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Super Moderator
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587 Posts
welcome to the forum, Cactus.
for starters, I would get some stock the size you want and practice to see what you can come up with.
my first start would be to cut a slice (noted in red) on the table saw then the bead-bearing bit in a hand-held router noted in yellow.
that's the easiest way I can think of without having a sample in hand to examine. some hand sanding will be involved.
are you going to replace the whole rail or just parts of it ?
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Super Moderator
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587 Posts
Cactus - don't know if you have it figured out yet or not . . . .
but, here is an example of what I came up with. making a short prototype, I used the flat bottom pattern bit to make the first cut (in red) and then I had to remove the bearing from my bead bit to get a deeper profile (in yellow). a clamped straight edge was used for both cuts as I don't have a router table so both cuts were free-hand.
with minor adjustments, you can come very close to the profile that you need.

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