I'm racking my brain trying to think of a way to make a perfect radius
corner.....about a half inch radius or so.
Is there any technique with a jig or something someone can share?
I really want an accurate, production setup to do these -- not a jig
saw cut and sanding etc.
There must be something?
(I don't mean a roundover edge -- I mean a rounded corner).
I have just about every tool known to man. problem is, the pieces I
have to get corners on are pretty small, about 7" x 2.5".
If it were a large piece, I could make a template and then use it as a
guide for my small laminate trimmer.
Maybe I'll have to try something like a dremel or roto tool.
That's not that small -- what's the hangup? If you need more support
for the router, make a jig that holds them that has an edge the same
thickness for the router to ride on.
On the shaper, a toggle clamp will hold them and run the template
against the guide bearing.
Then using one of your "every tool know to man" ;~), make a pattern
plate out of Masonite or MDF as a guide and use a top bearing pattern bit in
you router table, use the pattern on bottom of the piece needing the
I make a lot of kids toys and have to do this a lot.
I use a straight router bit with a bearing pilot that I use 1/4" thick
templates I lay over the material I have to round and just let the router do
It works with corners, curves and all kinds of shapes.
Simple, really, just very busy right now and wanted to get some hints.
Just start feeding the corner into the router till a "rounded edge"
template hits the bearing pilot, right?
And yes, I do have just about "every tool known to man".
It's just an expression.
"How do I make a perfect radius cut?" "Make a template with a perfect
radius and follow the template to make the cut?" Circular logic no?
There are easy ways to make an exact radious for the template but it
might be easier to buy a template made for that purpose. Look at the
lower template closely on the page link below. The outer corners are
all different radi so they can be used to do what you need. You can
use this template to make a better suited (size wise) template or use
it as it is.
Use a corner rounding cutter in your shaper or router table. Run the
workpieces by it, on edge, using a miter gauge or a push block against
the fence. You may need a backup piece to eliminate chipping. For
speed, gang the pieces.
Layout the radius. Mechanic sockets and a pencil work fine. Leaving
the line bandsaw the corners. An oscillating spindle sander does a
fast job sanding to barely touch the pencil line. Without a OSS, a
drum sander chucked in the drill press or disk sander with table will
do. Good lighting can make a difference.
I do it with a hardboard or MDF template and a pattern bit. I'll use a
coin or anything else that's the right size to trace and make the template.
In use, it's super fast and easy to use. If you're going to use it for
enough repetitions, adding "fence blocks" on the bottom side makes it
even faster to place on the work.
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