Rounding Corners?

[8way]

Just a quick question, what is the best way to round corners?

[prOk]

The *best* way is to make a template for the curve you want and then use a router with a templating bit to duplicate it as many times as you want..  an easier way is to use a disc sander to meet a profile you trace...    the easiest but cruddiest way is to use a normal orbital sander and sand the curve down.

[NiteWalker]

^ All are acceptable methods. I use the router and template method myself as it delivers the most consistant results. If you're really broke you can go the super cheap route and use a file or rasp to get it close to the line and a sanding block with 60 or 100 grit and sand it to the line. It's more difficult to keep the edges at 90 degrees, but it's the cheapest method I know of outside of using sand paper alone. It can be done with care.

Here's the resulting curves on mine:

[_) (V) (-)]

What if you need to have a 2-3" facing on the bottom edge of the control panel and wanted to round that as well?

[prOk]

So basically you want to mimic a bent metal control panel curve in wood?  You'll need a roundover bit for your router to accomplish that with any real degree of accuracy.

[Nannuu]

What if you need to have a 2-3" facing on the bottom edge of the control panel and wanted to round that as well?

You can run it through the table saw at three different angles (22, 45, 67) then sand away with and orbital sander.  I've done with with very decent results.  The easiest and most accurate way is described by pr0k above.

[Nannuu]

I'll try to explain my idea more.  Draw the curve you want on the edge of the part and set it up in the saw.  Adjust the blade so that you can get these three cuts (or two cuts if you don't want to run the board vertical).  Then sand away.  I sanded by hand, I don't reccomend this, it wasn't fun.  I was too cheap to buy a 3/4" roundover bit  .

[Nannuu]

Come to think of it, I think I only made one 45 cut and sanded from there.  That left the corner untouched.  Too hard to sand a straight line.  MDF is fairly easy to sand.

[MaMeNnO]

What if you need to have a 2-3" facing on the bottom edge of the control panel and wanted to round that as well?

You could also use a prefab rounded strip of wood. Like this:

[NiteWalker]

Another way similar to Nannuu's is to draw the profile you want on the edge, then use a small block plane to kill the corners till you're close. Then take to it with sand paper. If you have a router and roundover bit, definitely do it that way. Literally, the whole process takes a few seconds.

[ChadTower]

The router method is the one least likely to leave you staring at the thing forever thinking "it's not quite perfect, I should sand just a bit more".

[NightGod]

Best way to round corners?

Slow down to about 10-15 MPH and turn your wheel in the direction you want to turn. Once you get around the corner, let go of the wheel and let the car straighten itself out. It gets easy with practice.

[_) (V) (-)]

Did I mention this 'facing' was 3" deep in addition to the thicknes of the control panel?

I'm thinking this would be a little much for the router to chew on.

Maybe MamennO's idea of preformed strips, sandwitched between CP top and bottom panels, glued into place and then sanded till all were even. . .

I can't help but feel ChadTower's words echoing already.

[ChadTower]

You don't have to route it all off in one pass.

[_) (V) (-)]

I was refering to the depth a router is capable if cutting.

I'm not real experienced with the thing so I'm not even sure cutting 3" below the top plane is doable.

[prOk]

make yourself a router jig to cut the round corner..  use a jigsaw or other tool to get the bulk of the material off then just use the router to do the final trim to contour the rough cut.    If you make a jig you can flip it and cut half the distance from the top and then from the bottom no problem.

[ChadTower]

Just don't let anyone see you making the jig.  That would be embarrassing, with the legs flying around and arm swinging.

[prOk]

That's 'doing the jig'..  oh, wait, that doesn't sound too good either does it 

[_) (V) (-)]

Couldn't be that much more embarrassing than watching me ruin a bunch of boards with this router. 

Thanks guys!

[8way]

^ All are acceptable methods. I use the router and template method myself as it delivers the most consistant results. If you're really broke you can go the super cheap route and use a file or rasp to get it close to the line and a sanding block with 60 or 100 grit and sand it to the line. It's more difficult to keep the edges at 90 degrees, but it's the cheapest method I know of outside of using sand paper alone. It can be done with care.

I have zero experience with a router, but I just bought one and I been playing around with it. I

[Gambit]

You need to purchase a template kit for your router.

There are things that look like bushings that ride up along a template.

[8way]

Thanks Gambit , I got it now. Time to start raising my Router experience level.