Reply by OggieOglethorpe

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Posted on trying to duplicate an end trim.....any suggestions?

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1276 posts in 2956 days

#1 posted 07-27-2016 03:13 PM

What Wahoo said…

Rout a 180 degree bullnose on the edge of a board. Rip the 1/2 cylinder off. Repeat as necessary.

Glue the bullnose strips to a backer with flats oriented and sized to match the flat backs of the beads. In the case of your center photo, 7 flats to make the 90 degree turn. The flats closest to your edges match the mating surfaces, the center is 45 degrees to either edge, the two on each side between the edge and 45 are equal tilts. 0-15-30-45-60-75-90 degrees from one side… You can do the 15/75, 0/90, and 30/60 with the same setup by flipping the stock, if you think it through.

You could also glue up thin strips to form the base. Birch ply or MDF would be great for a glued up backer.

A third way to do this is to glue the bullnoses to a pair or three semi-circular “former” with flats as described above. Think “stringers and bulkheads” as in an airplane or boat structure.

Some factories had large shapers to make parts like this in one pass, which is probably how the original was made.

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