[bradbrad]

Sorry if this is too off topic - but when comes to the exposed roundover on the front sides of the AV3 cabinet, do you really need a router table to make that a clean edge, or is a hand-held router sufficient? 

My concern is that when I reach the end of the board, the roundover may try to slip off and make the edge look sloppy. 

I would think I could mitigate this by cutting the baffle slightly longer than needed, routing the edges, then cutting to final length.

Any thoughts?

thanks.

[WGH]

I would think I could mitigate this by cutting the baffle slightly longer than needed, routing the edges, then cutting to final length.

That would work. You can also clamp a straight board to the router base to act as a straight edge. Cut a 1/2 circle out in the center of the edge where the router bit is and line up the board with the bearing. I make router bases made from 1/4" mdf that are bigger than the original base so I have room for small c-clamps.

Or you can clamp a scrap board to the baffle edges so the bearing runs from the baffle to the scrap. One advantage to this method is it eliminates any chance of blowouts. If the baffle is solid wood, route the end grain first.

[Danny Richie]

A hand held router always worked fine for me with no issues.

[bradbrad]

Thanks fellas.