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Bettesworth Construction
router bits

A Template Means Never Having to Say “Oops”: A Guide to Repeatable Router Cuts

A shaped template and bearing-guided router bit can help reproduce a profile across multiple pieces. Learn how to make the template, set up the bit, and route the cut.

By Bettesworth Construction Team 2 min read
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A shaped template and a bearing-guided router bit make it possible to reproduce a profile across multiple workpieces—for example, four table legs with matching curves. The template guides the cut; careful preparation and routing still matter. WOOD Magazine describes the method and updated its article on March 4, 2025.

How template routing works

The template carries the profile you want. A router bit’s pilot bearing rides along the template edge, guiding the cutter around the workpiece. Once the template is made accurately, you can use it to cut the same shape on additional pieces.

This is a repeatability technique, not a guarantee that mistakes are impossible. The quality of the template, how securely it is attached, and how the workpiece is routed all affect the result.

Make and attach the template

  1. Choose template material. Use 1/4-inch hardboard or medium-density fiberboard (MDF).
  2. Cut the profile. Use a bandsaw or scrollsaw to cut close to the desired shape, then sand the edge to the line. The template edge will guide the bearing, so take care to make it smooth and accurate.
  3. Attach the template. Use cloth-backed, double-faced tape to secure it to the workpiece. Orient the grain for the best effect.
  4. Rough-cut the workpiece. Bandsaw the workpiece to within 1/8 inch of the template edge. This leaves a small amount of material for the router to remove.

Choose the bit and orient the template

The two bit setups differ mainly in where the pilot bearing sits. Match the template position to the bit type.

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Bit type Pilot bearing location Template position
Flush-trim bit At the tip of the bit On top of the workpiece
Pattern-cutting bit Between the shank and cutter On the router table

For a flush-trim bit, place the workpiece on the table with the template on top, and set the bit height so the tip-mounted bearing follows the template edge. For a pattern-cutting bit, the template rests on the table so the bearing between the shank and cutter can follow it.

Route the profile

  1. Ease the workpiece into the bit until it contacts the pilot bearing.
  2. Move the workpiece from right to left along the cutter, keeping the bearing against the template edge.
  3. If more than 1/8 inch of excess material remains in places, remove it with a couple of shallow passes rather than trying to take it all at once.
  4. Avoid pausing too long in one spot; the wood can burn. Inspect the routed surface before removing the template. If a spot is rough, make a further pass to smooth it.

When the stock is thicker than the bit’s cutting length

If the workpiece is thicker than the cutter can reach in one setup, WOOD Magazine describes a sequence using both a pattern-cutting bit and a flush-trim bit. The bearing follows the surface machined in an earlier pass.

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  1. With a pattern-cutting bit, make the first pass with the template side down.
  2. Remove the template and make another pass with the pilot bearing following the surface just machined.
  3. Flip the workpiece and use a flush-trim bit, with its pilot bearing following the previously milled surface.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.Support on Ko-Fi

Source and scope

The dimensions and procedure here come from WOOD Magazine Staff, “A template means never having to say ‘Oops’,” updated March 4, 2025: WOOD Magazine’s template-routing technique. The article provides practical routing guidance; it does not report a measured error reduction or a controlled comparison of router bits.

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