I'm working a new reel seat idea and hoping for some advise. I'm using 1 1/2" square stock and need to take out the center section, cross grain, leaving the ends full size, and leaving a 5/8" wide x 3/16" tall strip down the center (length-wise) of the dado (for reel feet). The only success I've had with accuracy is using a dado bit on the table saw, then cutting and gluing in a 5/8" strip from another piece of stock. I'm hoping to eliminate the need for a second piece of stock and the glue joint.

I've tried the routing table, but it's not quite precise enough and I need square corners. I've tried the band saw, but it's near impossible to rip that far on exotic wood and do it straight, plus I still need the strip from another piece. Chisels would leave too much to be straightened out with sandpaper. A sonic (oscillating) cutter would probably leave the same mess, but I am only speculating on this one. A mortising machine with the auger removed from the bit would do it, but I know it won't work without the auger.

I've run out of ideas. I'm hoping someone has been there and done that and come up with something better.

Jason Cosby
Cos Rods

there is a jig for a router that would do what you want. I have seen it but cant remember who makes it and it is expensive(kreg i think). i knew a guy that had one and used it for some really nice segmented and spiral turnings. shoot me an email and i will try to assist if i can. i believe i understand what you are trying to do and it is a tough one. i would consult with someone who has done segmented work if you have someone local. many times what we have in mind has been done in other forms of woodworking, just never applied to what we do. talk to other woodworkers and turners in your area or woodworking shop that can be invaluable in learning new techniques and applying things to our applications. either way let me know how it works for you. i would be interested if nothing else than my own curiosity.

Find a machinist with a vertical mill and that would be a piece of cake. A metal cutting mill will cut wood just as well as metal, I am using a metal cutting lathe to turn foam cores for grips, total overkill but it’s what I have and it works great.

Thanks guys. Great advise from both of you. Mike, you have my attention. I took a peak at some of the minis and micros, and I think you may have just saved me years of agony. Plus, of all things, I still don't have a drill press--other than a tiny jeweler's model. Considering I can mostly do away with the router (which I never got along with), do my fancy cuts, make metal parts, and be adding a drill press, I could drop some money on this thing. Any recommendations? The Sherline 5400 and Taig Micro Mill are looking pretty good, but I am a fish out of water in the mill arena. 100 pounds is the upper limit, since I'll have to move it around. I'm all ears and thanks again.

Jason Cosby
Cos Rods