[stoughto]

What strategy would you use to make a wooden switchplate?
I can drill the two mounting holes and use them to hold the piece down
while I'm milling it. What is the smallest diameter bit that is safe to use
for the rectangular switch hole?

I'll start working in pine and work up to red oak -- nothing exotic.

Thanks.

[valmet58]

its exactly what i did..worked fine.i used a 1/8 endmill..you will have to
finish the square corners by hand with a scroll saw..

[Geof]

.... What is the smallest diameter bit that is safe to use for the rectangular switch hole?...

On your machine can you orient the spindle and hold it in place.

If you can orient the spindle you could finish the corners by putting a little square file in the spindle and filing them with the machine.

[stoughto]

Brilliant. I'm used to thinking of the spindle spinning.

[Boots]

I just had to make a bunch out of Cherry for an entire home. I made them upside down on a long Cherry Blank. The back side I milled out with a 3/8 ball tool to get the radius near the edges. I roughed out the middle with a 1/4 in upcut and finished the pocket with 1/8 in upcut and the radius in the corner was perfect for the square receptical that it covers and drilled the 2 holes for mounting. I cut the OD out with a 1/4 in upcut and then sanded the parts out of the Blank because the blank was an extra 1/8 in thick so I didn't have to cut through. After the parts come out you can radius the face with a 1/4 round over bit in a Router set-up with a fence. They came out great...... and only take about a min. to make.

[rebaccawood911]

Its really great buddy thanks that even i can try it out with your measurements.....