How can I best (most easily) make the end of a 2×4 round?
I have a bandsaw, but it seems a bit awkward to maneuver a long board, and I would be restricted to cutting one 1/4 round and then the other.
I have a belt sander but it’s not a very happy camper, so I try not to use it for heavy work.
I have rounters, but not a 1″ round over. I guess I could buy one, but I would rather not have to for doing this to just a few boards.
Thanks
Replies
Bandsaw with something to support the back end to relieve most of the awkward maneuvering seems like the answer to me (table, roller stands, an extra person)
Jigsaw would also work, bring the tool to the work rather than the work to the tool, but sounds like that'd be another purchase.
There's also the option of handsawing.
I do have a saberjigsaw... I forgot about that option. Then finish off with the belt sander... I am just not sure about cutting the 4 inches necessary
1: If it just needs to be "roundish" clip the corners with a handsaw and break out a rasp.
2: If it needs to be a perfect radius perform #1 to get close to the line, then use a router with a template or trammel and a straight bit to perfect it.
do 2 inch-cut straight router bits exist for 1/4 router?
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Don't go there. Some things should not exist - just because it's possible doesn't mean it's a good idea.
A 2 inch long bit is very prone to vibration, even in a massive 1/2" router. Even with very light cuts there is always going to be chatter and of course, that is bad both for the workpiece and the tool.
Stick with the hand saw and rasp idea then polish with the belt sander. You can get both tools for less than a suicide bit and still have change.
As _mj_ described in 1 is how I would do it. Would be quick to do. If you don't have a rasp. A really good one is what is called Shinto rasp.
It depends on how accurate you need it to be and how many you have to do. If you need it to be as accurate as possible, then I would make a template and then do the cut with a router. If "cut by hand" is accurate enough, then mark an line on each side and cut to the lines by hand with a coarse rasp then finish sand it if needed. Either way use a small saw to remove as much waste as possible first.
Looks like mj and I were typing at about the same time.
Ya snooze ya lose!
Belt sander until it becomes VERY unhappy then buy a new one!
hummmmmm, tempting.
À 2 ft long 2 X 4 is hardly a long board. It could easily be roughed out on the bandsaw with a 1/4 ‘’ or less blade and sanded smooth with a Random Orbital sander or by hand with a block. An edge sander or a stationary disk sander would do this in no time but I doubt you have that.
There's a million ways to do it. You could do it with an emery board or a nail file. Whatever you have will work.
Whatever you do, mark layout lines, and work to the line. Even for something that doesn't need precision or to be pretty, it's good practice.
As a general rule of thumb if you need to make just a few of something its typically not worth the added time of making a jig or template. More often this is an opportunity to get some practice with hand tools.
Just as machine approaches achieve perfection from careful layout of the template or jig, the hand tools method relies on careful layout of the finish line with dividers, marking gages or marking knives. The journey to the finish line is optional. Whether you remove waste with a chisel, a rasp, a file or a hand plane or a combination of all three usually doesn't matter if the technique is well considered and executed.
With care, the final product made either way will not be discernible to inspection by anyone other than yourself.
On the other hand, if you are a tool nut, every project is also an opportunity to justify buying a new tool!
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Line a bunch up on a bench with the edges flush then clamp. Run the router over the ends then rotate and repeat. Quick and easy but you do need the bit. Buying more tools is always a plus in my mind.
+1 on router and template.
Keep the belt sander on the shelf.
Knock the corners off with your bandsaw and finish with a rasp and sand paper smooth.