feather grinding on router table?

[SOS]

Anyone try grinding feathers with a jig similar to using a drum sander but using a router table instead?  Seems like that could be very accurate and smooth.

[Tom Leemans]

That would be way too fast IMO. Do more burning than sanding. Don't even think about using some kind of cutting bit!

[Hog Wild]

Not with out a Router Speed Control like they sell at Habor frieght!!! And like Tom said don't even think of a cutting bit......

[Charlie Lamb]

Been using a router set up for years to process turkey feathers. No problems!

I use a rotary file for the cutting head.

[Kid]

Of course it would work. The only problem would be holding the feather tightly enough and setting up your cutting template with the right spacing. I've experimented with it a little, but didn't have a clamp to hold the feather well enough.  A spiral cutter with a template bearing will work fine.

[SOS]

Actually, I rigged up a setup this afternoon and it does great...almost.  Like Kid said, hard to clamp the feather tight enough.  The high vibration and the cutting can pull the feather out of the clamp.  Have to work on the that.  Otherwise, seems to work well - no burning for sure.  Charlie, you have a photo of your rig?

Steve

[todd smith]

Care to share any details of your set-up Charlie?

todd

[Charlie Lamb]

Todd... I'll hunt down the photos I have of my set up tomorrow and try to get them posted. It's a pretty simple outfit.

[SOS]

Thanks, Charlie.  Please include any info on your clamp to keep the power of the router from pulling the feather out.

[Charlie Lamb]

This took a while, but here are pics of my feather grinding set up....

Here's a feather held in the wooden grinding jig I made. I don't have any clamps on this jig however, a toggle clamp at either end would make it more positive in the way it holds the feather.

Hand pressure at either end seems to get the job done for me.
   

The jaws are curved to mimic the natural curve of the feather which I think helps hold the feather more securely.
I also line the clamping jig with soft material... in this case heavy canvas... to aid holding.
Course sandpaper or thin rubber could also be used.

[Charlie Lamb]

Here's the clamping jig in the open position.
 

[Charlie Lamb]

This is the cutting bit that I use. It's called a rotary file and has bearings above and below... they aren't really needed.
   

   

Note the tapered edge of the fence and cut out for the bit. I can adjust the fence for controlling thickness of the grind.

There's no burning with this bit, however the rib of the feather needs to be split fairly thin to expedite the process.

[Charlie Lamb]

How everything lines up.
 

The first pass is into the turning bit... slow and steady does it. I make a quick return pass to clean the grind and it's done.

[Charlie Lamb]

I built a jig for doing the side grind, but I prefer to just use a long pair of very sharp scissors for trimming the side.

I highly recommend using a dust mask when grinding feathers. It's pretty nasty stuff.

[Charlie Lamb]

To the top for Stephen and Todd.

[SOS]

Definite food for thought for the jig.  Did you make the "mini" table for the router as well?

[D. Johnston]

Hey Charlie, where did you find that bit? I've never seen one like it. Nice simple ideas there. Thanks, David

[Charlie Lamb]

Yep, made the mini table as well. A good friend gave me the bit, but you can get ones without bearings at machinist supply places.
I've got a new one that I want to make a shaft turning jig with.

[D. Johnston]

Charlie, I have been a woodworker for a long time and have never seen a bit like that in any catlog. I just spent the better part of an hour looking around on line and can't find anything close to that. Is that made for metal work? Can you give me a shove in the right direction. I can see several applications for a bit like that in my shop. But where can I find one? Any clues, hints, brand names, stores, suppliers, anything? Thanks, David

[Jeremy]

Hmmm, never seen a bit that big.  Looks just like a rotary burr on steroids!
I wonder if a rotary shaper (the microplane type) would work.  Thost can be picked up lots of places.
Love the mini-table Charlie!       He's right about the dust mask, but I'd also recommend to grind outside. I stopped grinding my own feathers - the dust was giving me lots of problems, even wearing a dust mask.  I was grinding in the garage with Both doors wide open - the little bit of time I'd have the mask off and kicking up the residual dust after the fact was bad enough!