As an experienced woodworker, begin by cutting your oak stock to size on a table saw. For a professional finish, chamfer the edges: set the blade to 45 degrees and shave off a thin sliver. Always use a standard throat plate for safety—skip unsecured clearance plates. Chamfer all required edges for a refined look.
On a router table, create a groove matching your aluminum bar's dimensions with the appropriate bit. Secure the oak with a featherboard against the fence for precise, clean cuts—essential for a seamless fit.
Smooth the groove with a random orbit sander and high-grit paper for a glossy finish. Place a rubber pad under the aluminum bar to prevent slipping. Insert the bar into the groove; tap gently with a rubber mallet if needed for a snug fit.
Fix the bar using contact adhesive, wood glue, or screws. For screws, pre-drill clearance holes and countersink them for a flush, professional result.
