Roundover size for Williams CP?

[TOK]

I'm building a Stargate/Defender bartop, and I'd like to duplicate the roundover at the front of the panel (Joust and Robotron also used this style panel).
Does anyone know what size roundover bit that would use? I have a 3/8" and a 1/2". I did a test piece, and the 1/2" looks good, but perhaps not quite enough. My router has a 1/4" shank and it looks like everything over the 1/2" roundover is for 1/2" shank size. 

[NiteWalker]

I think the 1/2" will work out fine. The best thing to do is make test cuts with different sizes and pick the one you think looks best. Like you said, unless you upgrade your router you're stuck with a max 1/2" radius roundover bit.

[TOK]

I looked at the 1/2" and while it looks OK, I think the original Williams must be 3/4" or larger. Since I'm going to be using an original Stargate CPO, looking at it will bug me forever. Looks like its time to spring for a 1/2" collet router!

[NiteWalker]

Good decision. 

Just a heads up though, large roundover bits can be pretty expensive.

[csa3d]

Would it be easier to find a wooden dowel in the diameter you want, then cut it into quarters on a tablesaw, then fasten all 3 parts together?  Can't say i've done this, but have thought about it.

-csa

[NiteWalker]

Cutting something completely round on the tablesaw is a risky operation. On top of that the dowel needed would have to be pretty big (1 1/2" diameter for a 3/4" radius, 2" diameter for a 1" radius, etc.). It can be done with the right fixture, but still risky.

[TOK]

Thats pretty clever thinking! Not sure I'm brave enough to do it on the table saw, but that idea got me thinking about quarter round molding, and if it was available in 3/4". Turns out it is. I'm still thinking about replacing my router just because I'm starting to experiment with it and I'm sure there are going to be other bits I want that aren't available in 1/4". I noticed the really long straight cut bits are only available for 1/2" too.

[NiteWalker]

1/2" bits give a much better cut than 1/4" bits by far. There's a lot of good routers out there that come with both collets. The quarter round molding sounds like a good idea.