Curvey Curves

**Evanism** · 3rd June 2013, 07:09 PM

Hello fellow scallywags, I need wisdom.

I received a commission last night and it is Not Going Well.

It's a kitchen sink cover, for a camper trailer. The small sinks used in 1 bedroom "bachelor" boxes in Sydney, but in this case in a camper-tent... The kind you tow in a trailer and unfold like an origami (presto! 4 man house in 15 minutes).

The cover is used so the sink can hold things during moving, but secondly so it can be used as a chopping board when unpacked (it's a little galley that unfolds into part of the "room"

Gosh, long description! Anyway, the trauma I have is thus:

- the board fits snugly in the top of the sink, which is angled and curved (it's an exaggerated kitchen sink)
- the commish wants it "deep" so I've made up a 28mm MDF... The deep part sockets into the sink sides so it's a reasonable press fit
- the top is significantly wider than the base

I thought to make up two templates, one for the top part the other for the lower. This is done. I would then use the router with the templates. This is done.

HOW The heck do you make 4 exactly curves on each corner? Is there some method I'm unaware of to get smooth edges that are all EXACTLY the same?

HOW do we cut EXACT curves and radiaii, other than awesome artistic skill and lots of sanding?

It seems to me this is very hard. (no wonder CNC is so popular)

**CMB** · 3rd June 2013, 07:22 PM

What radius are you looking at?

Craig.

**Handyjack** · 4th June 2013, 05:42 AM

Make a template for the curve and then use a flush trim bit. Template needs to be large enough for lead in and lead out and attaching.

**Trav** · 5th June 2013, 11:32 PM

Evan - is the problem that you need to cut a corner of a specific radius, with that corner also cut on a bevel? I so, I agree, that's hard.

Is another possibility to make the 'plug' from 3 different pieces of timber? One to fit in the sink, one to fit inside the rim and a top that would sit across the whole sink, possibly even with a lip sitting on the bench. See the attached pic to help explain it.

Finally, the MDF wasn't for the cutting board was it?

Trav

**Hermit** · 6th June 2013, 11:11 PM

Originally Posted by Trav

See the attached pic to help explain it.

Trav, your attached pic doesn't seem to be attached.

**Evanism** · 8th June 2013, 10:28 PM

Interesting how when you write something out it comes to you.

Like Trav suggested, I used 3 pieces of MDF, glued them together then made two templates, cut those carefully and then routed around the outside of those.

First time I have EVER used the routers "template hole cutting attachment thingy" (don't remember the actual term at this moment). After making the template, it was a minor thing to clamp it down and go over all the edges.

I was creative and matched the corners with tin cans, spice bottles and other round things. It took time to get the template right.

Trav, the chopping board top will be some hardwood fence pailings that have been drying for 12 months. At 67 cents each, they are VERY cheap and the wood, when chosen carefully, is remarkably good.

I ended up using the same trick to route a juice trench on a chopping board! Wife now happy

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