What's the Best Way to Round Over an Angle on My Speaker Enclosure?
Asked by CraftyNinja42
I'm working on a speaker enclosure made from 1" MDF, and it's designed like a rectangular prism with one edge that's chamfered at a 45° angle. This creates two external edges at 45° instead of the typical 90°. I want to round over all the external edges—no problem with the square edges using a corner round router bit. However, I'm stuck on how to handle the two angled edges. Is there a specific router bit for this, or should I just manually approximate the rounded edge with a belt sander?
Answers
You might need a custom router bit that has a parabolic curve for your specific angle. A larger roundover bit could help you get close, but honestly, I think the fillet option you suggested is the better route here since it might save you some hassle.
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If you can, consider getting a sandpaper guide printed or having the MDF machined to your specifications. This will let you skip the harder part and jump straight to putting records on and refining the insides!
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A belt sander is a bit too aggressive for those edges. Instead, try using a sanding block, like a scrap piece of 2x4, and just hand sand them. You’ll find it’s pretty easy! Those curved surfaces can be tricky, but as long as it looks good, you’re in business!
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