Harry and John, that was my original idea, but I thought this might be a good opportunity to learn how templates and guide bushings work and understand the math behind it.
Now that I understand it a little better, I think I can make a rectangular piece with square corners (on the table saw) that is 3/4" shorter and narrower than the opening. Then if I use a 1/4" bit with a 1" OD bushing, I will get a 3/8" offset on each side and the corners should be rounded with a 3/8" radius.
harry: yes, since i used a 3/4" wide bit, it has a 3/8" radius.
bob, I'm not seeing how I can use that to make the male part with rounded edges. That would result in a piece with square corners.
Last edited by Chris Curl; 11-27-2012 at 09:45 AM.