This tip was shared by Jodee from Inspire Woodcraft. It covers two clean, repeatable methods for creating consistent radius corners and chamfers—techniques that save time and deliver professional results.
Many woodworkers struggle with rounding corners consistently. Traditional methods like tracing paint cans and sanding by hand can be unreliable and inefficient. Jodee demonstrates how using templates or routing techniques can dramatically improve both accuracy and speed.
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Why Clean Corners Matter
Rounded or chamfered corners are common in woodworking projects where comfort, safety, and appearance matter. Poor execution can lead to uneven shapes or over-sanding that distorts the intended profile.
Jodee outlines two smarter methods to produce uniform results across multiple pieces—especially helpful for batch work or projects that require tight visual consistency.
Method 1: Templates Paired with a Router
The first approach uses a template made from MDF or engineered hardwood flooring. These templates can be traced, shaped, and refined to match a specific radius.
Once built, the template can be reused to produce identical results across any number of parts. A flush trim bit in a router follows the shape exactly, ensuring smooth and clean corners every time.
Templates can also be customized with alignment tabs. These tabs help position the template precisely at the corner of each workpiece, reducing guesswork and setup time.
Creating Multi-Purpose Templates
Jodee recommends shaping both corners of a single template differently. For example, one side might feature a large radius while the opposite side offers a smaller one.
This makes template storage more efficient and gives you options without needing to create separate pieces for each profile. It’s a simple way to stay organized while expanding your corner treatment options.
Method 2: Routing with Sacrificial Material
The second method is best for smaller radius or chamfer profiles. It involves attaching sacrificial material underneath the workpiece to support the router bit during the cut.
By routing from top to bottom—rather than sideways—tear-out is significantly reduced. The sacrificial piece keeps the edge clean as the bit exits the cut, improving results on delicate woods or detailed edges.
This approach is especially useful for final passes where edge integrity is crucial. It also works well for shop jigs and parts with small profiles that need a consistent radius or chamfer.
Sanding Without Losing the Edge
Even with clean cuts, sanding remains an important step. Jodee warns against using random orbital sanders on these features, as the soft pad can round over the profile unintentionally.
A better approach is to use a rigid sanding block that accepts 5-inch hook-and-loop discs. This provides better control and helps maintain the sharpness of the routed edge.
Hand sanding with the right tool keeps the shape crisp while allowing you to feather in any minor imperfections. It’s a small but important adjustment that makes a noticeable difference.
Reliable Methods for Repeatable Results
These two approaches—template routing and sacrificial support routing—help avoid guesswork and waste. Each method is simple to execute once set up and brings added precision to your workflow.
Templates can be saved for future use, especially if you regularly build similar pieces. The sacrificial routing method is a fast solution for unique shapes or one-off jobs where templates aren’t practical.
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