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Lucky me I have gotten to build two of these. I tend to drop the jig and it always lands on the wood and breaks.

I cut mine using a router. No big deal just built a piviot to connect to my router and cutting about 1/4" at a time cut the slot. Then I cut the finished piece out of the board. Did it this way so I would have plenty of wood to hang onto.

The piviot was no more than a sheet of 1/4" ply bolted to the bottom of the router with a hole with a pin through it the right distance from the bit.

Absolutely no big deal. Cheap, fast and dirty.

godavid2 wrote:I wondered how tricky it might be. Now I'm sure of it. I had thought about drilling the pilot hole for the slot and then routing the remaining arch. It would be free hand which is very tricky for me, anyway. I also wonder about mounting the routing bit from above. thanks for the help.

It is really not tricky at all.

I did it as you suggest except I used the drill press and a brad point drill bit. If I had an appropriate sized router bit, I would smooth it out use the router bit but I don't.

Did this once with SS, pivot board, in horizontal mode.

If I were to do it again, I would use the scroll saw(none here when the first was made). and use ss for the counter arc(the arc includes a clearance for the added washers).

More info than you probably want or need https://forum.shopsmith.com/viewtopic.php?t=8580