Teardrops n Tiny Travel Trailers

Id like to build a cabinet face out of a solid piece of ply with square cutouts that have 4 or 5" radiused corners. I was thinking i would cut and sand a template and use a flush cut router bit, but i feel there must be a more precise way of doing this. What techniques have you guys used?

4-5 inche radius is a pretty wide sweeping curve. If you were wanting to do someing thing a little tighter, you can use a hole saw to cut a round hole at each corner, then you just between the holes, leaving just the nice rounded corner. I have done this with corners up to 2" radius, using a 4" hole saw. I hope that makes sence, I am at work an really don't have a way to draw it.

Tom

Like this Tom ?



sorry about the size of pic, I;'ll need to work on that..................

Exactly!! I could have done that at home, but not here at work. Thanks for drawing that for me.

I have used this technique in the past and have been happy with the results. I think this will make a very nice template for the OP.
Tom

I went to the kitchen. No, not for a drink...

There are lots of round things in a kitchen, from canned goods to plates to cups and pots, lids and so on. I'd use a small can for a small radius and something larger for a larger radius. After that I cut out the hole with either my jig saw or my skill saw depending on needs. I also found that my cuts were much better when I followed either the outside or the inside of the line I had drawn. I preferred cutting to the outside of the line as the line would be left on the scrap rather than the finished product. Cutting on the line itself resulted in some modest wandering. Also, I found that working the cuts from the back side was best because it left prettier cut edges on the "pretty" side of the ply.