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Interior structural wood pieces - I want them to be perfectly flat

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javeryh:
Here’s what I do - check Post #7.

http://forum.arcadecontrols.com/index.php/topic,161994.0.html

thorr:
Thanks again!  That is very helpful.   When making the curves on the template, is it better to use my router with a cutting bit instead of a jigsaw so the edges are smooth?  I am not sure how controllable the router is when I slowly push it along a drawn line without a fence next to it.

javeryh:
This is why you should use 1/4” MDF for the pattern.  It can be sanded fairly easy.  Use your jigsaw to cut as close to the curved line as possible and then sand to the line using a block of wood wrapped in sandpaper or a sanding block if you have one.  You can make any shape you want this way.  I would not use the router to cut the template freehand - that is a recipe for disaster.  I use it to cut straight lines with a straight edge and pattern bit but not for curves (unless the arc is big enough for my circle jig but that’s probably overkill).

thorr:
Ok.  Thanks again! :-)

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