how do you guys create large curves on the front edge of your control panel?

[severdhed]

i've spent alot of time looking through the control panel thread for inspiration for my new 4 player panel, and i see alot of you have a nice curved front edge on your panels.  how are you creating these?  my current 2 player panel is just a rectangle, and i cant help but think the new one would look better with a curved front.  something like these...




i plan on just having a rectangular box under it, but i love the look of those curves,i'm just not sure how to draw it out and make it perfect and even like that.  i'm assuming you cut it out with a jigsaw and then sand it smooth.

how is this done?

[Breaker]

Hi there,

I agree that the curved front adds a nice aesthetic to a control panel.

While I don't know what others may have done, I ended up making myself a large router jig.
The radius of the curve on my control panel is 88 3/4" so that's a large jig to say the least;
I've attached a pic to give you an idea of the size...it's large but not unmanagable.
I've also attached a pic of my control panel prior to installing the controls to give you an
indication of what an 88" radius curve looks like - it's pretty close to the examples
you listed in your post.

If others have a more efficient means of cutting these curves I'd welcome their input.

Breaker.

[javeryh]

I would make a template out of MDF and get it perfect before cutting your actual panel out.  Other than making a crazy jig like Breaker, cutting 1/16" from your line and sanding it smooth is the way I would do it.  I'd also love to hear other ideas because so many of them come out so perfect I'm thinking there has to be some sort of trick to it.

[severdhed]

Hi there,

I agree that the curved front adds a nice aesthetic to a control panel.

While I don't know what others may have done, I ended up making myself a large router jig.
The radius of the curve on my control panel is 88 3/4" so that's a large jig to say the least;
I've attached a pic to give you an idea of the size...it's large but not unmanagable.
I've also attached a pic of my control panel prior to installing the controls to give you an
indication of what an 88" radius curve looks like - it's pretty close to the examples
you listed in your post.

If others have a more efficient means of cutting these curves I'd welcome their input.

Breaker.

that's what i was afraid of...

[DaOld Man]

I only have one thing to say about Breaker's jig:

Sweeet!!

[jimmy2x2x]

Couldn't you use an existing curve from something around the house or garage, clamp that item to your workpiece and run your routers base plate against that to produce the cut?

Although I am digging the monster jig!  How do you secure the jig?  do you have an equally monstrous workbench?

[bkenobi]

There are a few ways you can make curves.  None of them will give you a circle, but if you just want a consistent curve, they should work.  The 2 that are easiest are:

• Put a couple nails in a board and attach a string around them that's somewhat longer than the distance between them.  Use a pencil to draw a line at the extent of the string.  This will make a large oval.  It will take some experimenting to determine the right spacing and string length.
• Put 2 nails in a scrap "template" material.  take a piece of luan (or other thin wood) that's longer than the distance between the 2 nails.  deflect the center as much as you want and put a nail behind it so the 3 nails hold the bent wood in place.  As long as the wood is uniform, it will bend consistently and make a really nice arc.  If you want, you can add more nails spaced out evenly to make a different curve shape.  Trace the edge with a pencil.

[BobA]

Drawing a Large Curve

Sometimes it is necessary to draw a curve with a radius that is larger than which it is practical to use a compass.

Step 1

Mark the highest point at the center and the two lowest points at the bottom of the desired curve on a scrap piece of material, drive a nail at each mark.

Step 2

Lay a thin batten on top of the wood around the nails as shown and trace the curve.

[bkenobi]

Exactly...

[Breaker]

Hey all,

The jig was a 'hail mary' on my part but it did work well - I also tend to over-engineer so keep that in mind

jimmy2x2x  - I secured the jig on my deck outside. Cutting the arc was a piece of cake with the jig and, as
javeryh suggested, I then used this piece as a template to cut several other 'test' panels. To be honest, my
template required some minor tweaking (for squareness) even after using the jig, but once complete it can
be re-used any number of times to get a perfect blank.

I found that the problem wasn't so much drawing the arc as cutting it. However, use the suggestions provided here to get the curve you want and I'll bet you can get darn good results by rough-cutting with a jig-saw
and sanding to the finished curve line. Given the size of the control panel, and the likelihood that it will be finished in t-molding, hand-finishing would be a practical option...that is if building a monster jig you'll only use once isn't an attractive option

Breaker.

[Breaker]

....sorry - quoted instead of modifying....ignore

[BobA]

Exactly...

Sorry I think I said the same thing as your number 2 except with pictures.  It really does work well if the material bends easily.

[mlalena]

I actually put the line to cut as part of the control panel overlay.
Used a simple spline curve in the paint program and then mirrored it to make the sides match.

[Xb0x3r]

If you happen to have AutoCAD or something of the like, you can draw an arc and print it out full size, jigsaw along the line, and sand until the curve is smooth and gradual.

-Xb0x3r

EDIT: If you don't have AutoCAD or some other CAD software, PM me the dimensions of your control panel and I'll draw it up quickly for you. Also, for my CP I had access to a CNC router, so it made the lovely curve for me

[bkenobi]

Exactly...

Sorry I think I said the same thing as your number 2 except with pictures.  It really does work well if the material bends easily.

Yup, no worries.   

I was thinking about drawing a picture or finding a link to an article on how to do this, but I was simply too lazy to do it.   

[EvilNuff]

If you just need to do it once, as others have said print out whatever curve shape you want and rough cut and sand smooth.

If you need to do it more than once, then do the first part to create a pattern and for all future curves use the pattern with a router flush trim bit and cut it that way.