router jig for convex post top - Router Forums
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post #1 of 12 (permalink) Old 05-13-2012, 01:47 AM Thread Starter
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Default router jig for convex post top

I am trying to make a fixture so that I can make about a dozen newel post tops that are convex. I don't have a lathe which would be my first choice. Does anyone have any experience doing this with a router?
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post #2 of 12 (permalink) Old 05-13-2012, 03:40 AM
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Welcome to the forum, David.

What size are the post tops?

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post #3 of 12 (permalink) Old 05-13-2012, 06:48 AM
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Greetings David,

Welcome to The Router Forums!

I haven't done anything like you are suggesting with a router before, but it sounds like it could be a fun project. I look forward to reading what some of the masters that hang out in this forum have to suggest for a job such as this one, so thanks for posting your question!

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post #4 of 12 (permalink) Old 05-13-2012, 08:07 AM
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David what size stock are you working with? How far down from the top are you trying to remove? What shape are you trying to make in other words if one part is convex then the other would be concave. A picture or drawing would be helpful.
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post #5 of 12 (permalink) Old 05-13-2012, 11:12 AM Thread Starter
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Quote:
Originally Posted by jw2170 View Post
Welcome to the forum, David.

What size are the post tops?
The posts are 3 1/2 X 3 1/2" The caps will be 1 1/2" high with the top 1/2" rounded like a segment of a ball.
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post #6 of 12 (permalink) Old 05-13-2012, 11:23 AM Thread Starter
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I will get a drawing as soon as I can, probably Monday( tomorrow)
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post #7 of 12 (permalink) Old 05-13-2012, 11:48 AM
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David, as a gift several years ago someone gave me a book on making wooden chess pieces - it was a good book of ideas for making multiple bandsaw cuts on a workpiece that begins as square in section and gets cut in four passes - each rotated 90 degrees. After this initial shaping, sanding techniques bring the workpiece to completion. I have no idea of how one would do this with a router - safely, but maybe some of the "sanding" could be done with a router. I had a project similar to this several years ago and found great success using a cylindrical MicroPlane Cutter that is mounted in a drill press like one would affix a sanding drum. Be very careful if you do this, or the MicroPlane Cutter could give you a very memorable manicure! Have fun!

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post #8 of 12 (permalink) Old 05-13-2012, 11:56 AM Thread Starter
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Thanks, I am new at this pictures and or drawings will follow.
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post #9 of 12 (permalink) Old 05-15-2012, 07:10 PM Thread Starter
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Here are the pictures that I promised. The end result was that the pieces were faceted; rather than making a smoothe transition at the axises there was a ridge from the corner up toward the center. I sanded them the best I could but it wasn't a profesional job so I wound up sending the material out to be turned on a lathe. Oh well next time I will have to be more creative, this old dog can still learn a new trick or two. D.T.
Attached Thumbnails
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Name:	NEWEL TOP A.jpg
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ID:	52361  

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Name:	NEWEL TOP B.jpg
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Name:	NEWEL TOP C.jpg
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Name:	NEWEL TOP D.jpg
Views:	60
Size:	51.5 KB
ID:	52364  

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Name:	NEWEL TOP E.jpg
Views:	64
Size:	57.8 KB
ID:	52365  

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post #10 of 12 (permalink) Old 05-15-2012, 07:21 PM Thread Starter
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Quote:
Originally Posted by jw2170 View Post
Welcome to the forum, David.

What size are the post tops?
Here are the pictures that I promised. The end result was that the pieces were faceted; rather than making a smoothe transition at the axises there was a ridge from the corner up toward the center. I sanded them the best I could but it wasn't a profesional job so I wound up sending the material out to be turned on a lathe. Oh well next time I will have to be more creative, this old dog can still learn a new trick or two. D.T.
Attached Thumbnails
Click image for larger version

Name:	NEWEL TOP A.jpg
Views:	29
Size:	45.1 KB
ID:	52366  

Click image for larger version

Name:	NEWEL TOP B.jpg
Views:	27
Size:	47.4 KB
ID:	52367  

Click image for larger version

Name:	NEWEL TOP C.jpg
Views:	28
Size:	49.4 KB
ID:	52368  

Click image for larger version

Name:	NEWEL TOP D.jpg
Views:	27
Size:	51.5 KB
ID:	52369  

Click image for larger version

Name:	NEWEL TOP E.jpg
Views:	29
Size:	57.8 KB
ID:	52370  

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