We’ve been fretting about constructing our deck edge, having decided we needed the strength of a thin metal toe rail. First, we were going to shape it on our table saw in jigs and a metal cutting blade, then back to the old router routine. seen here:

This has routed surfaces on both sides, and–in fact–has three routed surfaces and a bulb to very tight and thin dimensions. You can see there are two of us taking care of everything while Bill carefully guides the router along. By the end of the day, we had one 12-foot section completely routed out, and three others almost so. We were so curious about the fit that we just had to dry fit this first piece in place, and WOW it really changes everything. We’ll show you profiles of both sides once we’ve filed and sanded the surfaces to perfection next week.