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?
3 Answers
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!
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!
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.