For a 1/4" radius use a 1/2" diameter bit. For a 1/8" radius use a 1/4" diameter bit. Make your template the size you need and use a top bearing bit or flush trim bit.
there is quite a bit of "wiggle room" you have there.
if you need to make minor adjustments, I would use
a rasp or file of some sort.
the flange will cover any unsightly cuts.
Edit: are you wanting to recess the flange flush with the box ??
normally, that is not done.
I have tried to illustrate how this handle was designed to be installed.
the yellow line is where the hole "should" be cut. the red line is way
out of bounds and swallows the whole handle assy. with no way to mount it.
the hole should be cut just inside of the screw holes, but not the whole flange.
and the corners can be square cut. there is no need to round them.
Alternate solution, not an answer to the question, my guess he is using a bushing in the router, don't know if it is visible from the back side, if not I would drill two starter holes and cut with a jig saw along the yellow lines, no template needed.
In that case you need a bit with the same radius as the corner on the handle, the guide bearing has to be the same diameter as the bit, a bushing will not work, the template can have square corners and has to be the same size as the recess.
agree with Frank, the bit radius has to match the handle corner radius.
you can use a bearing guided bit and the template opening is the same as the footprint, or a bushing where the template opening is increased by the difference of the bushing radius minus the bit radius on each side.
You are right, darn keyboard woodworking, wasn't thinking it through.
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