Cut A Radius In A Top Rail?

ecooke21

I need to cut a radius into the ends of a top rail on a porch I am building.. I normally would make a small template that "sits" on top of the rail, then I would jig it out.. But, This top rail isnt flat, it is curved at the top(the part you grab).. any ideas on how to get a nice smooth radius cut? btw its a 10" column

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A bunch of little rabbit turds banding together usually just makes one bigger piece of crap. -Mike Finley

troubleseeker

I would use the same method, just shape the bottom of you jig to cradle solidly on the profile of the rail, or easier, use rails under you flat platform to keep it from rocking.

Tom R

For something like that, - - I would normally just scribe a line, - - jig saw it a little to the outside of the line, - - and belt-sand it with the nose of a 14" or 16" belt sander.

Or, - - for a really perfect cut, - - you could also scribe a line, - - over-cut it a bit with the jig saw, - - then screw or clamp a 'spacer-block' to the underside of the rail that would would use to set it back the correct distance from your column to cut it perfect by running your router (base) right along the edge of the column.

You would just need a 2 1/2" or 3" straight-flute bit, - - and you'd set the spacer so the distance between your scribe line and the column is the same as the distance from your router base to the far side of your bit.

Although you would make 90% of the cut from 'left to right', - - you would first start at the other (right) end, - - and just cut in a quarter-inch or so to avoid getting a blow-out when you finish the cut, - - which you would then be starting from the other end.