Cutting and coping baseboard molding can be a time-consuming and fiddly job. This job is made much easier with a jig called “The Coper” which holds the baseboard while you cope it. Making a template for the Coper is not too difficult with the right knowledge. Here are the steps to making a good template.
Cut the Baseboard Pieces
Rub a thin layer of wax onto the edge of the 1-inch baseboard piece. Place it into the molding tray, wax side down, and the top is snug against the stop at the top of the tray. Cut ½ inch off the bottom of the other piece of baseboard to use as a relief block (the relief block can be cut out of other wood that is the same thickness as the bottom of the baseboard if needed). Rub the wax onto the relief block. Place the relief block firmly against the bottom of the baseboard.
Mix the Por-A-Kast
Ensuring the Por-A Kast is at room temperature, pour 2 tbsp. (30ml) of the Por-A-Kast Part A into one of the measuring cups. Pour 30 ml of Por-A Kast Part B into the other cup. Pour both parts into the mixing cup and stir for 20 seconds, mixing gently. Make sure you scrape the mixture off the sides of the cup while mixing. The mixture has a working time of 1 1/2 minutes when combined.
Make the Template
Making sure that the molding tray is level and stable, pour the mixture into the tray. After about 4 to 5 minutes, remove the template from the tray, leaving the baseboard attached. If it is stuck, just tap the tray or twist it gently so the template will fall out. Place the template aside for 10 to 15 minutes to harden. The exact time will depend on the air temperature. If you remove the baseboard before the template has hardened, it may cause the mold to shrink. You can just leave it overnight in the tray, once you have poured the template if you like.
Trim the Template
Remove the baseboard from the template. If any of the Por-A-Kast has leaked behind the baseboard, trim it off with a sharp knife. Run the router blade bit over the template edge to see if there is a spot that it cannot get into. If there is, use the file to lightly file this area to provide space for the bit. The templates should rarely require filing.
Place the Template into The Coper
Place the template into The Coper and screw it down. It needs to be firmly in place.
Make sure you are in a ventilated area while doing any molding, and wear gloves, and safety goggles.