As I work on a rug loom for my daughter, I was presented with the need to round the ends of the uprights that hold the loom. I thought of the method mentioned here about using a pattern to rout the raduis on the ends. Pieces are 3/4" thick pine and had planed to 2", within a hair (defined as +_ 0.002" by my pattern making friend) wide and had a 1/4" hole in the center and 1" from the end.
Based on how I could secure the pattern to the stick, I turned one disk from 1/2" thick MDF to 2" within a hair. I needed another MDF spacer down the stick a little for support on the router table and fortunately there is another 1/4" hole, 6" away. I used the same furniture bolts that will be used in the assembly and counterbored space for the heads.
I used the pattern disk to draw the radius and then lopped off the corners on the bandsaw.
The first stick radiused and the second set up and ready.
The finished radiuses. The bit burned the edges a little (actually "browned" them is more accurate), so I must have been going too slow, but even thought there wasn't that much stock to be removed, I didn't want to go too fast. I guess that is a "feel" that I have yet to learn. Sanding cleaned them up pretty quickly so they were not burned very badly. I didn't want to bother setting up the corner rounding bit again, so I "manually" corner rounded the radiuses.
I probably could have done this faster just sanding the radiuses to the lines, but this way was a lot more fun. I've had the new router and table for only two weeks but am pleased with how many things I've been able to use it for.
Rick