Step 1: How It Works
To ensure perfect templates: a bearing guides the radius cut, then a jointing-action flattens the adjacent side. I drilled a hole for a view of the cutting action.
Step 2: Plans
Free plans for the jig are attached!
Step 3: Hijack a Bearing
The bearing of a flush trim router bit is removed. This will be used (temporarily) to make the templates!
Step 4: Pick Your Radius
Pick the radius you want, and place the bearing accordingly.
Step 5: Set Up the Jig (1 of 2)
The corner of the jig should be in contact with the bearing.
Step 6: Set Up the Jig (2 of 2)
The edge of the jig should be parallel to the workpiece.
Step 7: Routing Action!
Pivot the workpiece around to make the radius cut.
Step 8: Trim It
Cut the template at the mitre saw to any desired size.
Step 9: Drill It
Make a hole so you can hold onto the template while in use.
Step 10: Cut Aluminum Angle
Two aluminum bits form the edges. A length of aluminum angle is cut at the mitre saw. Aluminum machines quite well with regular woodworking tools.
Step 11: Drill the Aluminum
Create two screw holes in each aluminum piece.
Step 12: Complete the Template
Screw down the aluminum angles.
Step 13: Make Any Radius!
The jig can make any radius template you can imagine.
Step 14: Happy Routing!
HIGH FIVE for reading!