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View BB1's profile

How to create a smooth edge for a curved opening

by BB1
posted 08-21-2016 08:10 PM


18 replies so far

View waho6o9's profile

waho6o9

8639 posts in 2941 days


#1 posted 08-21-2016 08:12 PM

Spindle sander

Files and sand paper is tedious work but the results are worth it.

View BB1's profile

BB1

1360 posts in 1212 days


#2 posted 08-21-2016 08:16 PM



Spindle sander

- waho6o9

Yes, that would be good..but, as of now, I don’t own one so that unfortunately isn’t an option. Maybe a reason to add another tool in the shop.

View BB1's profile

BB1

1360 posts in 1212 days


#3 posted 08-21-2016 08:23 PM

Files and sand paper is tedious work but the results are worth it.

- waho6o9


This is a possibility although I question my ability to make the two sides mirror images. Any hints on the best way to approach? Guessing slow and patient are key.

View waho6o9's profile

waho6o9

8639 posts in 2941 days


#4 posted 08-21-2016 08:41 PM

Guessing slow and patient are key.

Correct, equal amount of sanding until it’s pleasing to the eye. Tedious but worth it

View waho6o9's profile

waho6o9

8639 posts in 2941 days


#5 posted 08-21-2016 08:43 PM

These work okay but I find it difficult to get the opening symmetrical with them.

Hello files and sandpaper. :)

View BB1's profile

BB1

1360 posts in 1212 days


#6 posted 08-21-2016 09:18 PM

Yes…when I checked on cost for a spindle sander my husband laughed and said that would make for a pretty expensive tissue box holder! Looks like I better get to filing and sanding! :)

View MrUnix's profile

MrUnix

7361 posts in 2563 days


#7 posted 08-21-2016 09:30 PM

If it’s a one time thing – sanding, filing, sanding, filing some more, sanding… will get you there. If you plan on making more than one, a router, guide bushing and template would make it much easier. You only have to make the template once, and you can use your existing top (once shaped properly) to whip one out easily.

Cheers,
Brad

-- Brad in FL - In Dog I trust... everything else is questionable

View waho6o9's profile

waho6o9

8639 posts in 2941 days


#8 posted 08-21-2016 09:31 PM

Have fun

View BB1's profile

BB1

1360 posts in 1212 days


#9 posted 08-21-2016 09:57 PM



If it s a one time thing – sanding, filing, sanding, filing some more, sanding… will get you there. If you plan on making more than one, a router, guide bushing and template would make it much easier. You only have to make the template once, and you can use your existing top (once shaped properly) to whip one out easily.

Cheers,
Brad

- MrUnix


Will have to see how successful I am at getting this one with the filing and sanding. If it wasn’t for the odd shape, making a template would seem to be the way to go. When I see templates used on woodworking shows, it seems the templates just “appear”...I suspect that is the hardest part.

View MrUnix's profile

MrUnix

7361 posts in 2563 days


#10 posted 08-21-2016 10:07 PM

It would be easier if you made a positive template of just the oval shape first. Rough cut to shape and final sand on a belt or disc sander right to the line. Once you have the positive, you can use it to make the negative. Fortunately, you only have to go through the pain of getting it shaped properly once :)

I have a negative template to make these ovals on house signs:

(and a positive template for the fishy thing!)

And here are some positive templates for table number bases:

Alternatively, they do sell templates ready to go – if you don’t want to make them yourself. It will give you a limited choice of sizes, but one may be close enough to what you need.

Cheers,
Brad

-- Brad in FL - In Dog I trust... everything else is questionable

View BB1's profile

BB1

1360 posts in 1212 days


#11 posted 08-21-2016 10:26 PM

Brad – I can see how helpful that would be. Unfortunately as with the spindle sander…no belt or disc sander either (so many tools yet to be added to my shop!). I’m picking away with hand sanding and it is looking better.

View splintergroup's profile

splintergroup

2639 posts in 1586 days


#12 posted 08-21-2016 10:52 PM

I’ve always used templates and my router table. The template is cut into 1/4 masonite. Typically I’ll draw the opening onto a largish piece, then split it on the table saw through the center. This makes it easy to trim the waste up to the line with a bandsaw and makes it easier to shape and refine the curve (I do this with both halves aligned, back to back, in a vice, doing both halves at the same time). Start with a coarse rasp, go finer, finally use strips of sandpaper.

Once done, I’ll double-side tape the two halves to a new piece of masonite for the final template. The hole is cut out with a jig saw, staying just inside the previous template.

It is then to the router table with a bearing guided bit riding on the two part template, the masonite routes nicely.

All done! The wood parts are done with the one piece template double side taped in place, hole cut out as before. Watch the grain direction to avoid tearout (down-hill cuts). I use a bit with top and bottom guide bearings to make this easy.

It’s worth the effort if you plan on making more than several cutouts!

View Snowbeast's profile

Snowbeast

101 posts in 1702 days


#13 posted 08-21-2016 11:04 PM

A sanding drum on a Dremel tool works well and is easy to control. They are just a smaller version of what waho6o9 posted.

View BB1's profile

BB1

1360 posts in 1212 days


#14 posted 08-22-2016 12:10 AM

Thank you for the addition suggestions…no bandsaw or dremel (yet!). Obviously I need to go tool shopping. :)

View MrUnix's profile

MrUnix

7361 posts in 2563 days


#15 posted 08-22-2016 12:42 AM

Thank you for the addition suggestions…no bandsaw or dremel (yet!). Obviously I need to go tool shopping. :)
- BB1

Belt sanders and dremels show up on CL all the time in the $10-$20 range :)

Cheers,
Brad

-- Brad in FL - In Dog I trust... everything else is questionable

View tealetm's profile

tealetm

104 posts in 1221 days


#16 posted 08-22-2016 02:02 AM

I just picked up one of those spindle sanding kits for a drill ores and I’m pretty pleased with what you can do with it. I just used it on this stool for the arcs on the bottom.

Mark a line on the wood and sand to the line. You could use the attachment in a regular drill and clamp the drill up in a vice.

View BB1's profile

BB1

1360 posts in 1212 days


#17 posted 08-22-2016 02:38 AM

tealetm – nice step stool…and helpful to see what the sanding kit is capable of doing. Your project looks great.

Brad – will need to start watching CL for some deals!

View jerryminer's profile

jerryminer

951 posts in 1805 days


#18 posted 08-22-2016 07:00 AM

A router and template would be my choice. Much easier to sand a 1/4” mdf template than 3/4” solid hardwood.

And you can make just a “half template” then flip it over (or use a half-template to make a full template) and keep everything mirror-image.

If you don’t have a spindle sander or sanding drum, you can wrap a piece of sandpaper around a round object: dowel, pipe, soup can, ...

-- Jerry, making sawdust professionally since 1976

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