How to Make Window Casing

by JL Wilson

Step 1

Raise the table saw blade to a height of 5/8 inch. Secure the guide fence to the table on a 20- to 45-degree angle with 1 inch between the guide fence and the front of the blade; the more acute the angle, the tighter the cove radius will be.
Step 2

Lower the blade to a height of 1/8 inch. Turn the saw on and run the planks through the blade face down. After all of the planks have passed through the saw once, raise the blade another 1/8 inch. Repeat this process until each plank has passed through the saw five times.
Step 3

Sand the cove with an orbital sander to an 80-grit smoothness.
Step 4

Carve an edge detail along one edge with a router and profile bit. Push or pull the router along the edge of the plank in opposition to the blade's rotation.
Step 5

Sand the face, cove, edges and corners with an orbital sander to a 120 and then a 220 grit smoothness. Hand sand the edge profile to a 120 and than a 220 grit smoothness.

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3/4-inch thick by 4-inch wide hardwood planks Table saw Router Decorative router bit Orbital sander 80, 120 and 220 grit sand paper
3/4-inch thick by 4-inch wide hardwood planks
Table saw
Router
Decorative router bit
Orbital sander
80, 120 and 220 grit sand paper
Adjusting the distance between the angled guide fence and the table saw blade moves the cove closer or farther from the edge profile. Use a scrap plank to play with the cove's location before you shape all the planks to ensure the desired outcome.
Adjusting the distance between the angled guide fence and the table saw blade moves the cove closer or farther from the edge profile. Use a scrap plank to play with the cove's location before you shape all the planks to ensure the desired outcome.