cutting half-round posts - Woodworking Talk

mmwood_1 · 09-20-2008, 03:07 AM

Okay, let me try this question out on y'all. I have to cut some half-round posts to attach to the faces of some stiles. They will be cherry, 3" diameter x ~7 1/2' long. They are half posts which will be mounted to 4" wide stiles between several cabinets. There will be 4 of them. I have seen several brands of 1 1/2" radius roundover bits, and I will probably opt for one of those.They're whopping huge for a router and a little scary, but what the heck.
But then, at the top of the cabinet, there will be a horizontally mounted half-round, ~4" diameter, which will overhang the posts. It will be 13' long. Other than roughing it out and then using a plane/spokeshave and sandpaper to finish the shape, I have no other ideas as to how to make that. Any thoughts?

cabinetman · 09-20-2008, 03:57 AM

It may be worthwhile to find a shop that has a shaper, and preferably a shaper with a power feeder, and a 2" radius cutter. That will save you some time.

If not, you could cut chamfers as a roughout, and like you said use a handplane, not a spokeshave to shape the radius. What might help in the sanding process is a long block sander. I make mine from belt sander belts for either a 3"x21", or a 3"x24" belt sander. Cut a 3" piece of 3/4" or 5/8" sheet stock to fit tightly into the belt. Put a slight chamfer on the ends so it won't tear the belt when tapping the wood in. It will give you a flat sander 10"+ with two usable sides. They're quick and easy to make and you can write on the edge of the block with a sharpie, what grit paper is mounted. You could make several with different grits. They work great for many procedures.

mmwood_1 · 09-22-2008, 12:03 AM

cabinetman,
Yes, I will probably inquire at a few shops around to see if anyone has that equipment. I just wanted to post to see if I got any replies. If you look at my questions which I've posted in the past, I generally get only one or two replies. I don't know why that is. Am I being that difficult?
As for the long sanding block, yes, I've been using one like that for years. Thanks for responding.

pianoman · 09-22-2008, 12:25 AM

I would use a band saw...then a 4" drum sander. If you can`t find a 4" drum...turn one on the or a lathe...and use sticky back sand paper. Hope all goes well. Rick

pianoman · 09-22-2008, 12:55 AM

I think I misread...7and1/2`long...solid cherry...or laminated? Anyway, it sounds like you need to cope the half round into the rail. Is that right? Light industrial shaper to handle both plant-ons and nosing. If you buy the bits...do you have a router they will fit in? If so, do you have a variable speed adjustment...that sounds way too big for a router!! You explained what you`re doing...It sounds like a commercial project. Rick

mmwood_1 · 09-23-2008, 01:01 AM

Pianoman,
Actually, it's residential. And I do have a router which will handle the 1 1/2" diameter round over for the posts. But I think cabinetman is correct in advising finding someone with a shaper who can do the 2" radius.
As for solid or lam, I expect I will laminate 2 pieces together to obtain a full 2" thick stock. I generally cannot get that around here.