I have a drum sander to tackle the thickness (and flatness) of fretboards. It takes a few passes but there is no risk for tearout. Then I cut the fret slots. I make the radius using a router bit, usually…   Read more»

It should not chip if the blade is sharp enough, but yes, it is…   Read more»

@koendb 
I always make the radius before I cut the fret slots as I find using a plane can chip at the slots. 

@koendb I must admit, with the new long beam I bought it’s a lot quicker and I get really nice results, I think ideally I would plane first then use the beam. Best of both.

@nsj Yes I know you meant flattening, I just wanted to point out that you can also do the radius with a plane. I never get good results with sanding alone and it takes too much time 🙂