So my kid has lost a bunch of these shapes and I’m going to make a replacement set.
Does anyone have any ideas for how to get a consistent roundover on the corners? I have a router table but no CNC.
The square and rectangle I could do with a roundover bit and the blocks on their sides. But I don’t see any obvious solutions for the pentagon and triangle.
I’m totally fine just hand sanding these, but this kind of problem solving makes woodworking fun!
An idea that came to mind… I do have a 3D printer so I could make 120° and 72° round radius guides like these.
If you didn’t have a 3D printer, you could still print a template on paper, glue that to a board, saw/rasp/file/sand to the line and then use the shaped board as a template. Double sided tape should probably be good enough to keep it in place on your actual workpiece.
Router and template! Use a band saw or jig saw or even a coping saw to cut out the shapes in MDF or something. Use a 1/2" drill bit as a template and draw on your rounded corners. And then sand or file or rasp them to shape. THEN use a flush trim router bit and go to town!
Could you not just use a router pattern bit and use the actual piece as the template?
This is the way. Tape it down, route it out.
If you have a disc sander, you could make a jig that has a peg sticking out that you rotate the shape around the hole. Something that looks like:
If you don’t care about being perfectly exact you could use a Shinto rasp. Very effective and cheap
