Tutorial: Making Fascia Boards on a Shaper with Templates
Overview
This guide covers the complete process for producing multiple identical fascia boards using a wood shaper and template system. Template routing ensures consistency and efficiency when making production runs.
Materials & Equipment Needed
Tools & Equipment
Wood shaper (3HP or greater recommended)
Bandsaw
Pattern/flush-trim bit with bearing (matched to your profile depth)
Power feeder (highly recommended for safety)
Template routing jig or toggle clamps
Measuring tools and marking equipment
Materials
Template Material: 1/4" MDF or hardboard (Masonite)
MDF is preferred for clean edges and stability
Won't warp over repeated use
Inexpensive to replace when worn
Fascia Stock: Pre-milled to approximate dimensions
Attachment: Double-sided carpet tape or toggle clamps
Safety Equipment: Eye protection, hearing protection, dust collection
Part 1: Creating the Master Template
Step 1: Design and Layout
Draw your exact fascia profile on the MDF template material
Include any decorative profiles, curves, or details
Add 3-4" of extra length on each end for safe handling areas
Step 2: Cut the Template
Use a bandsaw or jigsaw to rough cut the template shape
Stay within 1/16" of your layout lines
For curved sections, cut slightly outside the line
Step 3: Perfect the Template Edges
Sand all edges perfectly smooth using progressively finer grits (80 → 120 → 180 → 220)
Use a sanding block on straight sections to keep them flat
Critical: Any imperfection in the template will transfer to every workpiece
Check edges with a straightedge for straight sections
For curved sections, ensure smooth, fair curves with no flat spots
Step 4: Seal the Template (Optional)
Apply a coat of shellac or lacquer to the edges
This creates a harder, more durable surface for the bearing to ride on
Light sand with 320 grit after drying
Part 2: Setting Up the Shaper
Step 1: Select the Correct Bit
Pattern/Flush-trim bit with bearing
Bearing diameter should match your desired finished edge
Cutter height must be at least as tall as your stock thickness
For 4/4 stock (3/4" actual): Use 1" tall cutter
For 8/4 stock (1-1/2" actual): Stack two 1" cutters with fanned edges
Step 2: Install and Set Bit Height
Install the pattern bit on the spindle
Tighten securely with proper wrenches
Set bit height so bearing will contact template while cutter shapes the workpiece
Use test piece to verify correct height
Ensure bearing rides smoothly on template without wobble
Step 3: Set Up Guards and Fences
Position the spindle guard with minimum clearance above the work
Adjust fence if needed for straight sections
Install starter pin for curved work (1/4" dowel in table near bit)
Safety First: Never operate without proper guarding
Step 4: Install Power Feeder (If Available)
Mount power feeder on shaper table
Adjust height so wheels contact workpiece firmly
Set speed to match your material and profile
Test feed pressure with scrap piece
Part 3: Preparing Workpieces
Step 1: Mill Stock to Size
Thickness plane all stock to final dimension
Rip to approximate width (leave 1/8" to 1/4" extra)
Cut to rough length (1-2" extra on each end)
Step 2: Rough Cut the Profile
Mark the profile on each workpiece using the template
Bandsaw close to the line - within 1/8" is ideal
The closer you cut, the less work for the shaper
Tip: Use a fence or guide block on the bandsaw for consistent cuts
Step 3: Attach Template to Workpiece
Method 1 - Double-Sided Tape:
Apply carpet tape to template in several locations
Avoid placing tape where bearing will ride
Press workpiece firmly onto template
Ensure no gaps between template and workpiece
Method 2 - Toggle Clamps (Safer):
Mount toggle clamps to template
Position clamps where they won't interfere with cutting
Place workpiece on template
Engage clamps firmly
Clamps double as handles for safer control
Method 3 - Sandwich Jig (Best for Production):
Create two 3/4" plywood plates
Template on top, workpiece in middle, backing plate on bottom
Secure with screws through waste areas
Provides excellent support and minimizes vibration
Part 4: Running the Shaper
Step 1: Safety Check
Verify bit is tight and rotating correctly
Check that guards are properly positioned
Ensure dust collection is running
Wear safety glasses and hearing protection
Secure loose clothing and tie back long hair
Step 2: Feed Direction
Always feed against the rotation of the cutter
For most setups: Right to left when facing the shaper
When spindle is reversed: Left to right
Never climb cut (feeding with rotation) - causes dangerous kickback
Step 3: Making the Cut
For Straight Edges:
Start with template against fence
Feed steadily at consistent speed
Keep firm downward and sideways pressure
Let bearing ride continuously on template edge
For Curved Edges:
Use starter pin for initial contact
Start cut at center of convex curves (working outward)
Start at ends for concave curves (working inward)
Maintain steady feed rate
Remove starter pin when flipping for reverse side
Step 4: Multiple Passes (If Needed)
For deep cuts or hard woods:
First pass: Use larger bearing to take lighter cut
Second pass: Switch to smaller bearing for final dimension
This reduces tear-out and cutting forces
Always make final pass in same direction for consistency
Step 5: Grain Direction Considerations
Ideal: Cut with the grain (downhill)
For pieces with changing grain:
Take lighter cuts
Use sharp cutters
Consider using spiral cutters for smoothest finish
May need to make relief cuts first
Part 5: Quality Control & Tips
Inspection Checklist
✓ Smooth, consistent edges with no tear-out
✓ All pieces match template exactly
✓ No burn marks (indicates proper feed speed)
✓ No chatter marks (indicates stable setup)
✓ Clean corners and transitions
Troubleshooting
Burn Marks:
Feed rate too slow
Cutter is dull
Solution: Speed up feed or sharpen/replace cutter
Tear-Out:
Cutting against grain
Cut too aggressive
Solution: Take lighter passes, sharpen cutter, adjust feed direction
Chatter/Vibration:
Workpiece not secure to template
Template too thin or flexible
Solution: Better clamping, use thicker template backing
Inconsistent Results:
Template edge damaged or worn
Bearing not riding on template consistently
Solution: Repair/replace template, check bearing condition
Pro Tips
Make test cuts on scrap before running good stock
Keep cutters sharp - dull cutters cause tear-out and burn marks
Feed consistently - variable speed causes inconsistent finish
Support long pieces with roller stands or helper
Clean bearing regularly - pitch buildup affects accuracy
Mark template orientation - ensures consistent grain matching
Number your pieces - maintains order for assembly
Save your templates - label and store flat for future use
Recommended Shaper Specifications
Minimum Requirements for Fascia Work
Motor: 3 HP or greater
Spindle Sizes: 1/2" and 3/4" (interchangeable preferred)
Speed Range: Variable speed or 3,000-10,000 RPM
Table Size: Minimum 20" x 24"
Reverse Capability: Highly recommended
Popular Shaper Brands
Powermatic (PM2700, TS29) - Professional grade
Delta (HD Shaper, X5) - Industry standard
Jet (JWS-25CS series) - Good mid-range option
Grizzly - Budget-friendly alternative
SCMI (T110, T130) - High-end European quality
Conclusion
Template routing on a shaper is the most efficient method for producing multiple identical fascia boards. With proper setup, sharp cutters, and attention to safety, you can achieve professional results with excellent consistency across your entire production run.
Key Success Factors:
Perfect template preparation
Secure workpiece attachment
Proper feed direction and speed
Sharp, well-maintained cutters
Unwavering attention to safety
Remember: The template is the foundation of quality - invest time in making it perfect, and every piece will reflect that precision.
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