Rounded Corners

[kuato2084]

Hey Everyone,

Not sure if I'm posting this in the right section, but here goes. I am very new to wood working so bare with me. I am trying to build an arcade cabinet I designed in sketchup, but I'm having trouble figuring out the best approach to make the rounded corners. I am attaching a pdf of the design for those who need to see what I am trying to do. I never used any power tools, but did buy a Festool Track saw, Festool jigsaw. I printed out a 1:1 template at fedex to trace over where i need to cut. I will start by cutting the design over a 1/4 inch mdf that I want to use as a template for a router that I don't have yet. Any suggestions on how to make nice rounded corners according to my design. Please keep in mind I am very new to this so simple easy to follow explanations would be great. Thanks for all the help.

 

[nclemmons]

First Welcome to FOG!

I think you are on the right track - full size template printed and traced and then cut out with both the track saw and the jig saw. 

The nice thing about a track saw is you can line the rail edge up against the template drawing and cut the angles very easily and accurately.  That will get most of the cuts done.  The balance, you can do with a fine blade in the jigsaw. 

i'd use adhesive sandpaper on a block of wood to round the corners as a simple way that would still give you control to sand to the line.  Then you can use the cut-out template with a bearing guided router bit to copy the template onto the wood for repeatable designs.

If you had an oscillating spindle sander, that would be another alternative for rounding the corners but looking at the design, there are very few to really deal with.

Good luck!

neil

 

[kuato2084]

First Welcome to FOG!

I think you are on the right track - full size template printed and traced and then cut out with both the track saw and the jig saw. 

The nice thing about a track saw is you can line the rail edge up against the template drawing and cut the angles very easily and accurately.  That will get most of the cuts done.  The balance, you can do with a fine blade in the jigsaw. 

i'd use adhesive sandpaper on a block of wood to round the corners as a simple way that would still give you control to sand to the line.  Then you can use the cut-out template with a bearing guided router bit to copy the template onto the wood for repeatable designs.

If you had an oscillating spindle sander, that would be another alternative for rounding the corners but looking at the design, there are very few to really deal with.

Good luck!

neil

Thanks Neil for the quick response. This is the approach I will take. By the way I have the standard blades that came with the psb300 jigsaw would this be ok or would you recommend the use of another blade ? Thanks!

 

[tjbnwi]

I would not use MDF for my template, the edges will not hold up. 1/4" or 3/8" plywood, I use MDO ply. It is used for making signs, very flat and durable.

Follow neilc's directions to get the template right.

Tom

 

[RonMiller]

I always chuckle when I'm asked to bare with people. I really don't want to get naked to do woodworking...that could be dangerous.



But I'm very willing to bear with folks and be patient.  ;D

 

[JoggleStick]

There are many ways to skin the cat. I've used mdf for templates for years. Yes it's not as durable, but on the other hand it is easier to get a 'smooth' edge.
If you are concerned, make a master template, then cut your job template (only) from the master template. If you accidentally kill the job template- cut another from the master. This will give you a back up and is not a bad way to go- especially for a first timer.
You can sand those curves by hand- just have a good line and sand to it or for greater accuracy...
For the inside curves- try wrapping some sandpaper around a dowel of the correct dia.
For the outside you can stick some sandpaper inside a cut section of plastic pipe.
Sand the sequence- coarse say 40-60, 80, 120, 180.... Should be plenty for template.