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Thanks for all the advice. I will try lots of different options and report back. I do some volunteering for the National Trust and we are always clearing Holly, so I have access to lots of material to practice on, although it will now be not until next winter before I have more wood.

Have any of you got any advice about seasoning Holly, especially to retain its white colour? I have tried in the past but it has always turned a dirty khaki colour. I can rough turn it really thin and have it distort, or rough turn it, both of which keep the whiteness. I want to make some boxes...

The new bearings have arrived and been fitted to the cutters. I have also turned down teh speed on teh router, which may help with vibration etc. So far I have cut quite a few trial joints which all worked out well with no problems and I am now trying out all teh nuances of teh jig to get the...

Thanks for all the advice. The new bearings arrived yesterday and I will hopefully have a chance to give it a go again on Monday. I understand what you are saying about speed and resonance etc, so I will set the speed down a notch and see if that helps. I will keep you informed of progress.

I have a Gifkins dovetail jig that I have not used very much at all, and today I experienced a repeat of a problem with the bearing below the router cutter head. I have my router securely fixed in a table and today when using the jig, the bearing started to come apart. I think it is just a dust...