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View Full Version : Getting Rounded corners on a small Solid Box with a Pin Router (Pics inside)


Nick Sorenson
12-17-2009, 6:18 PM
I'm trying to make a template to cut the corners of a small solid box on my pin router. I can cut the box to shape 4x6 easily on my RAS but I'd like to take it a step further and pop it into a template jig to round the corners (don't like pointy sharp corners:)). Anyways, I had an idea and it didn't quite work. See below:
http://img705.imageshack.us/img705/4593/dsc0001c.jpg (http://img705.imageshack.us/my.php?image=dsc0001c.jpg) http://img38.imageshack.us/img38/1996/dsc0002xo.jpg (http://img38.imageshack.us/my.php?image=dsc0002xo.jpg)
http://img704.imageshack.us/img704/4594/dsc0003t.jpg (http://img704.imageshack.us/my.php?image=dsc0003t.jpg)
http://img109.imageshack.us/img109/7047/dsc0004jx.jpg (http://img109.imageshack.us/my.php?image=dsc0004jx.jpg)


Is there a way to accomplish what I'm shooting for? I suppose I could flip an actual 4x6 box on end and use a 1/4" round over on each corner and use that as a template but I don't like the possible danger there. And beyond that I'd like to learn something. Any ideas that would work?

this is going to be an enclosure for an overdrive pedal (for guitar) that I'm going to try to produce.

What I was trying to do was round the edges of the box. I would attach it to the back of the template and route the 4 corners. What I ended up with is the inside just has 4 square corners. In other words, I didn't accomplish anything:(

thanks in advance!!
harry strasil
12-17-2009, 6:26 PM
You need a larger radius on the inside of the jig corners.
Nick Sorenson
12-17-2009, 8:18 PM
You need a larger radius on the inside of the jig corners.

Yep that's the problem... there is no radius on the inside of the jig corners (the strips brad nailed to the pin side of my template being made).

I guess that's my problem. But I'm looking for a good way to get the radius I want when making templates.
Myk Rian
12-17-2009, 8:54 PM
Make an inside template with the rounded corners.
Double-side tape it to the stock.
Ed Kilburn
12-17-2009, 9:15 PM
Nick a quick way to fix the fixture you now have is to drill a hole 2x (radius wanted on the part + router bit diameter) and drill a hole in a scrap part the same thickness as your rails you nailed on. Then draw a square around the hole touching the edge of the hole with each side. Cut on the lines and you should have 4 cove parts, glue them in each corner and you are set to go.
If you need a drawing, I can post one later tonight.
Nick Sorenson
12-17-2009, 11:12 PM
Nick a quick way to fix the fixture you now have is to drill a hole 2x (radius wanted on the part + router bit diameter) and drill a hole in a scrap part the same thickness as your rails you nailed on. Then draw a square around the hole touching the edge of the hole with each side. Cut on the lines and you should have 4 cove parts, glue them in each corner and you are set to go.
If you need a drawing, I can post one later tonight.

Man a drawing would be awesome! If you get the time. I'd love to see more on your idea.
Ed Kilburn
12-18-2009, 10:27 PM
Nick
I did this with my electronic wood shop.
First to decide the diameter of the hole to drill.
Example you want 1/2" radius on your finished part, and you were using an 1/2" bit to cut them out. 1/2" + 1/2" = 1" times 2 = 2"
So drill a 2" hole. Them draw a square around the hole touching the edge of the hole with each side. Cut on the line of the square, and you should have 4 cove parts. Then glue them into the fixture you made and rout away. :)
Nick Sorenson
12-19-2009, 8:31 AM
That is great! Thanks. Is there an easy way to center a square around a circle? Sorry if that's a dumb question.
Gerry Grzadzinski
12-19-2009, 8:45 AM
That is great! Thanks. Is there an easy way to center a square around a circle? Sorry if that's a dumb question.

Draw the square first. :)
Ed Kilburn
12-19-2009, 1:44 PM
If you start with a square cut on the end of the board, use a square and the 2 square edges.