I'm currently working on a speaker enclosure made from 1" MDF. The design is almost a rectangular prism, but it features one edge that is truncated at a 45-degree angle, resulting in two external edges that aren't the standard 90 degrees. I need to round over all of these external edges. While it's straightforward to use a corner round router bit on regular square edges, I'm unsure about how to effectively round over the two angled edges. Is there a router tool that can help with this, or should I just resort to manually trying to shape it with a belt sander?
3 Answers
Another option is to have a sandpaper guide printed or even get the MDF machined to what you need. This way, you can skip straight to enjoying the final product and focus on adding some tunes and perfecting the internals!
You might want to consider a custom router bit designed for parabolic curves that fits the angle you need. Alternatively, a larger roundover bit could get you close enough for sanding, but honestly, I'd recommend just going for the fillet method, which is more straightforward and might save you time.
Using a belt sander might be a bit too aggressive for this type of work. I recommend grabbing a sanding block, like a piece of 2x4, to hand sand those angled edges. It’s actually pretty easy, and you can achieve a nice, consistent curve that looks good. Remember, if it looks good, then it is good!
That's a solid idea! I might try to make a specific sanding block from a few laminated MDF pieces, giving it a 135-degree angle with a routed roundover. That should help with accuracy!