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Bettesworth Construction
rounded corners

How to Make Rounded Corners With a Router

Use a template and bearing-guided bit for broad, repeatable corners; choose a roundover bit by radius to soften a sharp edge.

By Bettesworth Construction Team 3 min read
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For a broad, rounded corner on a shelf or tabletop, use a smooth reusable template and a bearing-guided router bit. For a small curve along an edge, use a roundover bit sized to the radius you want. The methods are different: a roundover bit softens an edge, while a template guides the router around a larger corner.

Choose the right method for the corner

What you want Method Best fit
A broad curve at the end of a shelf or tabletop Template, rough-cut, then bearing-guided pattern or flush-trim bit Repeatable corners; handheld router or router table, depending on the bit and setup
A small, consistent curve along a sharp edge Roundover bit selected by radius Softening an edge rather than shaping the whole corner

Make a wide-radius corner with a template

A template gives the router a consistent path and makes matching corners repeatable. Its curved edge must be smooth: imperfections in the template will transfer to the workpiece.

Make and prepare the template

  1. Choose the corner radius and mark the curve on 1/2-inch or 3/4-inch plywood or MDF. Use a compass to mark the arc.
  2. Cut on the waste side of the line with a jigsaw. Sand the curve to the line with 80- or 100-grit sandpaper until it is even and smooth.
  3. Attach edge guides or fences far enough from the curve to stay clear of the router and bit.

Transfer and rout the corner

  1. Trace the template curve onto the workpiece.
  2. Rough-cut the waste close to the line, leaving a small amount for the bearing-guided bit to remove. For a router-table setup, Woodcraft’s method calls for sawing to within 1/8 inch of the line.
  3. Choose the bit and setup to match your equipment. A top-bearing pattern bit lets the bearing ride on the template with a handheld router. A flush-trim bit with a shank-mounted bearing can be used with the template on a router table.
  4. Keep the workpiece firmly against the template and its fences while routing. Make a test cut on scrap first.

A carefully sanded template and bearing-guided bit can reproduce the same corner on multiple pieces. Do not try to remove all the excess material in one aggressive pass; follow the router manual’s guidance on multiple passes for your tool and material.

Use a router table and flush-trim bit

For small tabletops and shelves, Woodcraft contributor Marvin Mertz describes using a 1/2-inch hardwood-plywood template with two fences set back from the curve. The template guides the workpiece as it passes the bit.

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TOTOWOOD Roundover Router Bit Set,4pcs Router bit Set,1/4 inch Shank,Radius in 1/8", 1/4", 3/16", 5/16",Bearing Guide for Rounding Edge bit (4pcs Roundover Router Bit)
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  1. Trace the template onto the workpiece and saw away the waste, stopping about 1/8 inch from the line.
  2. Install a flush-trim bit with a shank-mounted bearing and position the template so the bearing rides against it.
  3. Hold the workpiece firmly against both fences. Move it against the rotation of the bit; do not make a climb cut.

This arrangement depends on stable workholding. If you cannot keep the stock firmly against the fences throughout the cut, stop and improve the setup before routing.

Soften an edge with a roundover bit

A roundover bit’s stated size is the radius it cuts: for example, a 3/8-inch roundover bit cuts a 3/8-inch radius. Common sizes cited by WOOD include 1/16, 1/8, 1/4, 3/8 and 1/2 inch. Choose the radius that matches the profile you want; a 1/4-inch bit is one common general-purpose size, not a requirement.

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  1. Set the bit so the bottom of its concave cutting edge aligns with the router base or router table.
  2. Test the setup on scrap of the same thickness. Too much bit projection can leave a ridge, or fillet; too little can leave the radius incomplete.
  3. Adjust the bit as needed and rout the workpiece only after the test profile is satisfactory.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.Support on Ko-Fi

Feed direction, workholding and cut quality

Secure the workpiece and keep the bit clear of it when starting the router. Feed against the bit’s rotation. For outside edges, the Grizzly H7790/H7791 manual specifies counterclockwise feed; for interior holes, it specifies clockwise feed. Avoid a climb cut, where the cutter moves in the same direction as the feed: the router can lunge forward.

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  • Make test cuts on scrap before routing the finished piece.
  • Use multiple passes as appropriate to reduce chip-out, burning and the chance of the router jerking from your hands.
  • Keep hands and clamps positioned so they cannot enter the bit’s path, and maintain control of the workpiece throughout the cut.

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