Trying to install brass splines on walnut tray corners

[Intex]

I used the OF1010 to cut sample spline slots on a sample miter joint, before I cut on the semi-completed tray. the brass sheet is approx 3/32" + a little. I first used a 1/8" Spiral down cut bit, and the slots were too loose for the spline. I then used a 3/32 spiral down cut bit on the router, and the slots are too narrow. Whenever I sand them, I do not get an even line, so the spine does not look good when inserted. Any ideas how toi enlarge the slot width?  The jig is not accurate enough to move the bit over just a little, and I cant find a straght file that thin to file it wider. Any ideas?

Also brass sheet is way harder than I thought!!

 

[Cheese]

A photo of the jig/fixture would help.  [smile]

My first thought, having not seen the jig, would be shim stock.

 

[Intex]

The jig is a rockler spline jig
I will try the shim idea, but I am afraid everytime I loose, then tighten the jigs frame holder, it is not precise enough to go back to the original setting b+ shim

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[cgrutt]

How about grinding a 1/8" double flute bit to correct size?  First pass with the 3/32 spiral finish with the ground bit?

Alternatively would a 3 mm straight bit work? https://www.amazon.com/Freud-Double-Flute-Straight-04-508/dp/B000P1ATX2

 

[Cheese]

Shim stock should work.  [smile]

Say the slot you route is .010" too thin for the brass sheet.
1. Place the wooden frame in the jig, making sure the router bit is in the position you want.
2. Loosen up just one end of the plastic jig and throw two .010" thick pieces of shim stock to support both legs of the frame.
3. Move the plastic supports in to firmly hold the frame legs and the shim stock.
4. Make one pass with the router bit
5. Now, without loosening anything on the plastic jig, remove the shim stock and place it on the other side of the wooden frame in the jig.
6. You've now moved the frame over .010" from the initial cut.
7. Make another pass with the router bit and it should be .010" wider.

 

[Intex]

The idea of the 3mm bit is one I didnt think about, but a need a longer one than that on Amazon
I tried putting in 2 thin Brass shims on one side of the piece, routing the slot, then removing the 2 shims, but your idea of just moving the shims to the other side seems easier, Ill try that next!
Thanks!

 

[Cheese]

I tried putting in 2 thin Brass shims on one side of the piece, routing the slot, then removing the 2 shims, but your idea of just moving the shims to the other side seems easier, Ill try that next!
Thanks!

Ya, if you snug up the frame & the shims in the jig, so everything is tight, then by moving the shims to the other side of the frame means the fit will still be tight but that the frame has been offset by the thickness of the shims from your first cut. Good luck.  [smile]

 

[RKA]

Put the shims on the right side first, then the left.  (Avoids a climb cut onthe second pass). Not sure if it will matter much, but it can’t hurt.