Face milling with the router

Step-by-step guide to surface routing wood
Whether you are a beginner or an experienced woodworker, every detail counts when surface routing wood. With a router and planer, you can level and smooth even large and challenging workpieces. In this guide, you'll find out what options are available without a jointer or planer and how you can create impressive projects. We'll show you which tools you need, how to proceed step by step and give you professional tips to ensure your results are of the highest standard.

Facing a beam with a router

Face milling on the RUWI lifting table

Navigation

• How to face mill?
• Preparation
• Instructions
• Machine selection
• Tool selection
• Face milling devices
• FAQ

The most important facts at a glance

• Tool selection is crucial: Choose the right routing tool and a compatible router, complemented by effective dust extraction.
• Preparation pays off: Thoroughly prepare the workpiece, face milling device and safety precautions.
• Observe the technique: Pay attention to the milling direction and speed to minimize tears and increase the surface quality.
• Don't forget the finishing touches: Check the surface, sand it, and apply a protective finish if necessary (such as oil, wax, or varnish).

How can I plane with the router?

In face milling, the upper surface of a wooden workpiece is processed with a router and a special face milling tool to make it smooth and even. This is an alternative to working with a jointer or planer, especially for larger workpieces such as tree slices, epoxy resin tables or solid wood panels.

Finished workpiece after face milling

Preparation: What do I need for face milling?

In order for face milling to be successful, you should have the necessary material and tools to hand as well as some preparation time. The following list will give you some orientation:

Material list

• Workpiece (e.g., solid wood cutting board, tree trunk slice, epoxy resin table)
• Vacuum cleaner or extraction system
• Dust mask and safety goggles
• Stable work table or workbench

Tools

• Clamping jaws or positioning aids
• Face milling cutter (corresponding diameter)
• Face milling device
• Powerful hand-held router or pole router

Instructions: Face milling with the router

Here we show you step by step how you can quickly and easily plane uneven solid wood workpieces. You can achieve precise results with a router, a suitable router bit and a surface routing device.

Step 1: Tool selection

Choose a router and router bit that are suitable for your project and material. Commonly used face cutters have two or three cutting edges and a diameter between 30 mm and 40 mm. Larger ones (up to 50 mm) are also available, but they require very powerful routers. A professional face cutting jig that we recommend is the SlabMatrix from sautershop.

Festool Router in Detail

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Step 2: Prepare the machine and tool

Check the router and router bit for damage or wear. Insert the face mill into the collet until it reaches at least the mark, and tighten it securely. Pay attention to the preset speed and ensure that it never exceeds the router bit’s maximum speed. Then attach the machine to your face milling jig, if one is provided.

Note: Caution—sharp tool edges. Wear gloves when assembling, if necessary.

Step 3: Preparing the face milling device

Make sure that your router jig is mounted stably on the work surface. Check the height and alignment so that the router maintains the desired routing depth as it glides over the workpiece. Remove dust and dirt from the guides. If your jig is adjustable, adjust it to the size of the workpiece. A correctly adjusted jig prevents vibrations and ensures consistent results.

Facing a tree pit using clamping devices

Step 4: Prepare the workpiece

Use a sturdy workbench and, if necessary, a non-slip mat. Align the workpiece and shim it if it wobbles. Secure it firmly using clamps, clamping jaws, or eccentric clamps. If working with scrap wood, check for nails, screws, or other foreign objects to prevent damage and safety hazards.

Height adjustment of the router on the SlabMatrix

Step 5: Milling the wood flat

Start at the highest point of your workpiece. Move the router in straight lines at a steady pace. If possible, route in the opposite direction. If a section has already been planed, you can lower the bit by 2 to 3 mm and continue until the entire surface is flat. Do not remove too much material in a single pass to avoid overloading the machine.

Effective dust extraction during face milling

Tip: You can learn more about synchronous and counter-rotating operations in the encyclopedia article on milling processes.

Note: A lot of wood dust is usually produced when face milling. Use a dust extractor and wear a dust mask.

Step 6: Finishing the wood

Check the surface for milling marks and any irregularities. Then sand it with 100- to 150-grit sandpaper, followed by 220-grit or finer. Thoroughly remove the sanding dust before treating the surface with oil, wax, varnish, or stain. This will give the piece the necessary protection and a beautiful finish.

Machine selection

Choosing the right machine is a decisive factor for precise face milling results. Common options:

• Handheld router: Suitable for a wide range of tasks. Models with variable speed are particularly versatile. For many woodworkers, they are the “Swiss Army knife” of routers.
• Rod milling machines: Often particularly robust and powerful, ideal for large wooden panels or hardwoods. The height is usually only adjusted via the face milling device itself.

RUWI motor for the rod milling machine

Tool selection

• Two or more cutting edges: Fewer cutting edges are ideal for moderate material removal, while more cutting edges are best for large surfaces and fast work.
• Fixed-tooth cutters or indexable-insert cutters: Fixed carbide cutting edges are often more affordable, but they must be sent out for sharpening. Indexable-insert cutters allow for easy turning or replacement of worn cutting edges.
• Shank diameter: Common sizes are 8 mm, 10 mm, and 12 mm. Make sure they're compatible with your router.
• Tool diameter: Face milling cutters range between 25 mm and 50 mm. The larger the diameter, the more power and stability the milling cutter needs.

Always choose a milling tool that matches the scope of the project and the specifications of your machine.

Face milling devices

Face milling devices are the key to precise and even face milling. Various versions are available:

• Simple face milling jigs: Ideal for DIY enthusiasts or small projects. Provide a basic guide for the router, but are usually only suitable for smaller workpieces.
• Professional surface milling tables: For demanding or commercial applications. Sturdy construction, built-in dust extraction, precise height adjustment, and, where applicable, adjustable stops. Suitable for larger workpieces and highly precise surface milling.

SlabMatrix on the RUWI lifting table

The decision between a simple DIY solution and a professional surface milling table depends on your needs, budget, and desired level of precision.

Learn more in the Woodworking Encyclopedia: Face Milling

FAQ

What is face milling?

Flat milling is a woodworking technique in which a router, a suitable flat milling cutter, and a flat milling jig are used to mill the surface of pieces of wood until it is flat and smooth. This allows for the removal of unevenness and the achievement of precise thicknesses.

Which router is suitable for face milling?

A router that is suitable for face milling should be powerful enough to drive larger face milling cutters and have a precise depth setting. A variable speed is helpful in order to be able to react to different materials. Ergonomics and good dust extraction improve working comfort.

How do I avoid tear-outs when face milling?

Preferably mill in the longitudinal direction of the wood fibers, use a sharp milling cutter and adjust the speed accordingly. If necessary, use a splinter block to support the exit edge. This will keep unsightly tears to a minimum.

Do I need a special face milling device?

Yes, a face milling device is necessary to precisely control the milling depth and remove the workpiece evenly. It ensures reliable results and prevents unwanted vibrations or skewing.

Which face milling cutter is the best for my project?

This depends on the material, the desired surface quality and the frequency of use. Routers with reversible blades are easier to replace when worn. Be sure to pay attention to the shank diameter, cutter diameter and the permissible speed of your router.