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post #1 of 9 (permalink) Old 09-11-2012, 04:58 PM Thread Starter
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Default Hi from Rod

Hi folks,

Thought I'd sign up and see what routing tips I could harvest from fellow members!

I'll start off my quest for knowledge with a poser...
I earn my living from designing and building small craft storage items, but a problem I have never been able to solve satisfactorily, is how to round over the inside edges of small through holes. I have tried bearing guided round-over bits, the finger and sandpaper method and those little arbor mounted grit balls. All these methods work (grit ball seems to give the best finish but they seem hard to find and only available up to about 25 mm diameter!).

Thus far, I have had to round over both sides of almost 10,000 holes using one or other of the above methods (with no end in sight!)

So...
Does anyone have any suggestions (other than employing someone to do it for me!)? Does anyone sell grit balls in various sizes (to suit holes from 14 mm up to 40 mm diameter).

I'll be interested to see if anybody can come up with suggestions (before I reach senility and the rest of my hair falls out )

All the best,

Rod
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post #2 of 9 (permalink) Old 09-12-2012, 11:15 AM
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Default Rounded Edges

Would it be possible to do the desired job with a counter-sink bit or a bit used for de-burring small holes?? Either or, very inexpencive.

"Even bad decisions make good stories"

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post #3 of 9 (permalink) Old 09-12-2012, 05:04 PM
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Welcome aboard. Yeah, countersink was my first thought too.
A picture or two of what you make would probably be helpful too. And, why exactly do they need to be rounded over?

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post #4 of 9 (permalink) Old 09-12-2012, 09:46 PM
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Hi Rod - welcome to the forum!

I don't have a 'good' solution (since you've already tried many), but just wanted to join this thread to see if an easy option is offered by others?

Just made a wall shelf for a friend to hold his Blu-Ray player and an Apple TV unit - drilled several holes about 1 1/4" (using a hole saw on my drill press), and wanted to also round over or chamfer the top inside edge of the 2 holes - well, could not find an easy solution other than hand sanding; THUS, any help would be appreciated!

Dave
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post #5 of 9 (permalink) Old 09-13-2012, 08:02 PM Thread Starter
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Originally Posted by JOAT View Post
Welcome aboard. Yeah, countersink was my first thought too.
A picture or two of what you make would probably be helpful too. And, why exactly do they need to be rounded over?
Thanks for your response!

I'll try and sort out a pic or two (seems I have to upload to a file host first. before attaching to this thread) - having said that, all my items are on my website: creations-by-rod.co.uk (I'm not able to post URLs directly yet!)

And... the reason they need to be rounded over is to give the product a more "finished" look and also to avoid the user getting small splinters - I finish all my items to 240 grit and supply them untreated (the holes are used to store various small craft bottles).

Cheers, Rod
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post #6 of 9 (permalink) Old 09-13-2012, 09:19 PM
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Rod, the answer you are looking for is the Mini Mop, a 1" diameter version of a sanding mop. The starter kit includes a mandrel you chuck into your drill motor. All varieties of sanding mops have special sandpaper which has been perforated into strips. When you first install a new mop you must break it in by running it against some scrap wood to seperate the strips and allow them to curl. Once they are broke in you just give a quick sweep across your holes and the sharp edges seem to melt like warm butter. Sanding mops are great for any type of profile or shape. Here is a link to one source in Canada, there may be others in the UK now that you know what to look for.
.: Stockroom Supply :. 1" Mini Mop Kit

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post #7 of 9 (permalink) Old 09-14-2012, 09:49 AM
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Quote:
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Rod, the answer you are looking for is the Mini Mop, a 1" diameter version of a sanding mop............[/url]
Thanks Mike for the suggestion above; now I've seen these in stores but never bought one! Now on the Klingspor Website and will put in an order for the smaller mandrel & a couple higher grit 'flutter sheets' (the term used there for the sandpaper strips). Dave
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post #8 of 9 (permalink) Old 09-15-2012, 12:10 PM Thread Starter
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Quote:
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Rod, the answer you are looking for is the Mini Mop...
Thanks for your input Mike - I never realised it would be so difficult to find a tool to do this relatively simple job with!

"...sharp edges seem to melt like warm butter..." - love the description!

Right, I now off to check out the links and explore the possibilities - wish me luck.

Cheers, Rod
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post #9 of 9 (permalink) Old 09-15-2012, 01:24 PM
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Don't thank me for this suggestion, BJ was the one who found and shared it. Rockler sells the large sanding mops but I have only seen the one source for the mini mops.

Mike
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