Today in the shop (rounding the corner)

[reible]

I've been noticing that this section, Beginning Woodworking is a little light on posts. I figure there has to be a few people who would like to see more posts in this area so here is one.

I have a project that I did last year thinking it was going to be very temporary, a year later and it still in use. So now I'm going back and doing a few things to improve upon the woodworking. One of which is to round a corner. I'll take you though the process and perhaps you might find some value to the effort.

So here is the corner:

IMG_3010sc.jpg (254.67 KiB) Viewed 14825 times

Now there are plenty of ways to "design" the radius, cup, plate, can, and jar to name a few. And yes I've used that and more, but I do have this thing:

IMG_3011sc.jpg (124.04 KiB) Viewed 14825 times

One corner has 1", another 1-1/2", another 2" and then the last corner is 2-1/2". It made of plastic but if you wanted to make one plywood or something similar would work as well. Notice the small metal bits on the sides? Well they rotate to provide stops like this:

IMG_3012sc.jpg (132.71 KiB) Viewed 14825 times

With the correct corner and stops in place you simply slide it in place so the stops rest on the edges.

IMG_3013sc.jpg (317.85 KiB) Viewed 14825 times

You can then mark the radius like I did here:

IMG_3014sc.jpg (271.45 KiB) Viewed 14825 times

At this point you can cut the radius with say a scroll saw, coping saw, and well just about any tool can work even sanding. In this case I used a hand held jig saw to do a ruff cut. Since I had "other" plans for finishing the corner I didn't attempt to get very close to the line.

IMG_3015sc.jpg (357.18 KiB) Viewed 14825 times

Next I attached a couple of pieces of double sided tape.

IMG_3016sc.jpg (270.54 KiB) Viewed 14825 times

Now putting the template back in to position and having it held with the tape I'm ready to route the corner round and know it will have a nice smooth finish and professional look.

The router bit of choice is a pattern bit. Note the bearing that is the same size as the cutter mounted above the cutter. This bearing will ride on the template and the cutter is adjusted to cut the wood. Piece of cake to do.

IMG_3017sc.jpg (132.2 KiB) Viewed 14825 times

Results:

IMG_3018sc.jpg (277.64 KiB) Viewed 14825 times

Light sanding and we are ready for paint.

If you have questions ask away.

Ed

[algale]

Thank you, Ed. That looks like a useful jig! Did you buy it or make it?

[reible]

Thank you, Ed. That looks like a useful jig! Did you buy it or make it?

This one I purchased a long while ago, it was cheaper then if I were to purchase the material and make it then. Now with the cutting boards I get at Sam's Club it might be another story.

One other thing I didn't mention was that the drawing of the line and the jig saw cutting are not necessary needed, you can go right to routing the round if you wish.

Ed

[jsburger]

Thank you, Ed. That looks like a useful jig! Did you buy it or make it?

This one I purchased a long while ago, it was cheaper then if I were to purchase the material and make it then. Now with the cutting boards I get at Sam's Club it might be another story.

One other thing I didn't mention was that the drawing of the line and the jig saw cutting are not necessary needed, you can go right to routing the round if you wish.

Ed

That is nice to have four radii on the same jig. I have made single jigs. The latest is the one I made to round the corners of the bench planks for my 10ER restore.

[rjent]

I've been noticing that this section, Beginning Woodworking is a little light on posts. I figure there has to be a few people who would like to see more posts in this area so here is one.

I have a project that I did last year thinking it was going to be very temporary, a year later and it still in use. So now I'm going back and doing a few things to improve upon the woodworking. One of which is to round a corner. I'll take you though the process and perhaps you might find some value to the effort.

So here is the corner:

IMG_3010sc.jpg

Now there are plenty of ways to "design" the radius, cup, plate, can, and jar to name a few. And yes I've used that and more, but I do have this thing:

IMG_3011sc.jpg

One corner has 1", another 1-1/2", another 2" and then the last corner is 2-1/2". It made of plastic but if you wanted to make one plywood or something similar would work as well. Notice the small metal bits on the sides? Well they rotate to provide stops like this:

IMG_3012sc.jpg

With the correct corner and stops in place you simply slide it in place so the stops rest on the edges.

IMG_3013sc.jpg

You can then mark the radius like I did here:

IMG_3014sc.jpg

At this point you can cut the radius with say a scroll saw, coping saw, and well just about any tool can work even sanding. In this case I used a hand held jig saw to do a ruff cut. Since I had "other" plans for finishing the corner I didn't attempt to get very close to the line.

IMG_3015sc.jpg

Next I attached a couple of pieces of double sided tape.

IMG_3016sc.jpg

Now putting the template back in to position and having it held with the tape I'm ready to route the corner round and know it will have a nice smooth finish and professional look.

The router bit of choice is a pattern bit. Note the bearing that is the same size as the cutter mounted above the cutter. This bearing will ride on the template and the cutter is adjusted to cut the wood. Piece of cake to do.

IMG_3017sc.jpg

Results:

IMG_3018sc.jpg

Light sanding and we are ready for paint.

If you have questions ask away.

Ed

Thanks Ed, I always find your how-to posts helpful. Thanks for posting.

[ERLover]

Yep used a many a radius thingy, yogurt containers, paint cans of various sizes anything that was round and fit the bill.

[garys]

That definitely makes the job easier. I don't have anything like that so I have always ended up doing it the hard way.

[mbcabinetmaker]

One great thing about woodworking is there are usually several different ways to accomplish the same task. I round a lot of corners and this is my preferred method for small to medium sized pieces.

1.jpg (267.91 KiB) Viewed 14368 times

First I use a corner marking jig to mark all 4 corners.

2.jpg (350.59 KiB) Viewed 14368 times

Next I set up a stop on the miter saw to clip the corners at 45 degrees.

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Then trim as close to the line as I can.

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Now I have set up the sander on the Shopsmith with a flip top stand to help support the work.

[mbcabinetmaker]

5.jpg (362.56 KiB) Viewed 14363 times

The belt sander makes quick work of sanding down to the line.

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Total sanding time for all 6 pieces was about 9 minuets.

[ecom1]

Question for you Mark: I see you have a Festool hooked up for dust collection on the sander - do you use if for other Shopsmith SPTs as well, or just for sanding operations? If so, how would you rate it for the other tasks?