I am trying to make crosses 1 1/2" x 2 1/4". Material is 1/4" x 3' hard wood. Band saw cuts my pieces and I bought a drill press to make the holes in the sides. I trying to make a half lap joint on my router. I bought the bit, but my problem is the pieces are so small there is no way to hold them and cut the joints. What do you suggest?
You need a Jig.......something to hold the wood pieces while you slide the router......
Start with a worktable or piece of plywood........
On this screw on two "foot" long pieces of wood parallel to each other....Like RailRoad Ties....Keep the space between them close to your cross/stock size......
Next screw two "Rails" to the ties.....space these to accept the router base.......keep them 90º to the ties for accurate crosses......
Finally use the router with the desired bit (at a shallow cut) to cut a notch in the jig sides when the router slides between the rails........This notch will always remain consistant with the same bit/router adjustment.....just slide the router between the rails.....
When cutting out the work consider cutting the notches while the stock is LARGE.....Plan the cuts carefully and cut several cross/notches at once.......then use the bandsaw to cut the separate pieces and fine tune the joints with sandpaper.....
use a wooden wedge/shim to hold the stock tightly in position within the jig
"...measure once.....cut twice....throw that one away and cut a new one...."
Moderated by Mark Hammond 
