Adding a ROUNDOVER to Plywood Corners - Corner EDGEBANDING with splines

so i'm in the middle of a project and i just came across a problem i am building a cabinet using this walnut plywood and everything's already cut to size and like dados are routed and everything and i was originally going to assemble all the corners using miters which would be totally fine but then i had a change of heart in the design i decided that i wanted to add really big round overs to all the corners which i think could look really cool but if i did that on this plywood after mitering it you would see the exposed plywood in the corners which could look cool just not for this project so i have to figure out a way to hide that plywood on those corners so if i would have thought of this round over idea before buying my material i probably would have just bought a lesser grade plywood and then did the miters and then the big round over and then veneer it on top of that but we're here now and i have to figure out how to make this work with what i already have going on here so i think i thought of something that in my head seems like it's going to work so let's figure it out this is a 5 8 inch round over bit that i'm going to use it's a pretty big round over as you can see from this test piece over here and what i did on this side is i raised the bit higher than what you normally do when you do round over leaving that little lip there so that i could take my combos square and measure to see if it's actually 5 8 and it was so i took some walnuts stuck and ripped them to be a little bit bigger than 5 8 inch wide and then i flipped the pieces on to the other side to make them 5 8 inch square i also did some extra pieces here just because you never know what's going to happen something might get messed up so i just always make sure to mill up some extra pieces as i'm doing it and i also was not sure if i wanted to do a matching color or a contrasting color so i milled up some lighter pieces as well so i cut these pieces to slightly bigger than 5 8 just to give me some wiggle room in both directions so i'm just going to line this up on the ply make some marks actually i'll do some test cuts on some scrap i'm going to put a tiny little chamfer on the inside of all these pieces and that's going to help bring all the pieces together and make up the difference from this edge piece i'll just keep lowering the bit until i get to the correct app that i want the router is now set based off of the scrap that i used and now i can just add that teeny tiny little chamfer on the inside corners of all of these pieces now i have a quarter inch slot cutting bit at the router table and a scrap piece of poplar that i meld to the same dimensions as all those other pieces and i'll sneak up on the fit i want to get in the center of all these pieces i'll just keep making passes on the scrap until i get to the location that i want now i'm not going to change anything with the setup at the router table yet and i'm going to do a test cut on that piece of plywood that i already made that test chamfer on the only thing that i'm actually going to do is i'm going to push the fence back a little bit just to cut a little bit deeper into the plywood but i'm going to keep the height the same all right so here is a spline that i just roughly cut fits really nicely in the groove and the plywood that i just cut all right so what i have here is that the plywood and the hardwood are perfectly flush with each other which is pretty good but what i actually want to do is i actually want to make the hardwood just a little bit proud of the plywood just to give me some wiggle room so that i could clean up the hardwood in case there's any inconsistencies and if this is perfectly flush and then i need to sand or fix something i might have to sand away the veneer of the plywood and that's no good so i'm going to take that that router bit and i'm going to raise it a little bit so that the groove in the plywood is slightly higher and that way the hardwood is going to sit just slightly above the plywood so i just adjusted the bit and that's what i'm going for a very very slight reveal so i'll be able to clean up that hardwood just in case there's any inconsistencies before moving on i just want to do a test fit just to see if i want to do the walnut which is matching or do the lighter color which would be a contrast so first i'll try the walnut just to see how that looks okay so that fits really nicely and i think it looks pretty good so i know it's definitely not fooling anybody it does not look like it's continuing all around it definitely looks like a filler piece so that's why i wanted to try out a lighter piece to see maybe if i just go with the fact that it's a filler piece and do a contrasting wood so let's try that out now okay so i like it but not for this project i think that maybe for this project this is going to be too busy to have stuff going on on the doors of this whole thing um i like that it's showcasing that i'm using a filler piece like i'm not trying to fool anybody here and it's going it's like a cool accent piece but just not for this specific project i'm gonna go with the walnut all the pieces are ready to be glued up now and i did a dry fit trying to put everything all together at once and that was a complete disaster so i decided that i'm going to break it down into sections so first i'll just glue the filler pieces with the splines onto the side panels and then i'll take those these side panels after the glue dries and then i'll attach it to the top and bottom and hopefully breaking it down like this is going to make this glue up just go a little bit easier just put everything into place first i left everything oversized and i'll trim that all up after the one important thing that i need to be aware of during this glue up is that the uh the grooves in all the pieces are facing in the correct direction so that direction is in towards the case so on the side of the where i drilled all these holes for the shelves you guys didn't see me do that but um all of those little details are going to be in the full build video for this project i should also mention that when i cut these splines i made them slightly narrower than um the the gap between the the two grooves that way there's just a little bit of room for glue in there so this is why when i was making the grooves in the hardwood and the plywood i offset it so that the hardwood was sitting slightly above the plywood so you see over here my nail is catching on the hardwood edging which is how i set it i actually wanted it to be raised a little bit because over here on this end it's completely flush and my nail isn't catching on the hardwood at all so if i would have tried to aim for perfection and tried to comp like line up the hardwood completely flush with the plywood this little part over here would probably be lowered down and sitting below the plywood which means i would have to sand at the veneer and that might expose some of the plywood in inside and that's no good so when i'm doing stuff like this i try to just assume that there's going to be some sort of inconsistency in either material and i tried to think beforehand of how i should prepare the pieces so that i can just clean them up afterwards and then make it perfect after it's all together and also in this corner right here is why i made that little tiny little chamfer on the inside corners of the plywood pieces it's to make up the difference of the thickness from the hardwood edging and the actual plywood now i know a lot of people are probably going to ask why didn't i just make the hardwood the same thickness as the plywood and then i wouldn't have to make that chamfer and that's an excellent point so you could totally do that but i really wanted to try to make the roundover start exactly where the hardwood is going to start so this is all just an experiment i'm gonna do a mock up a test piece where it's the same thickness and see what that looks like also probably should have done that before gluing everything all up but here we are before i add the round over on the edge here and see what it all looks like i'm going to put on this molding piece i'll show how i made this in the full build video but basically this is going to help continue the curve that's going to go on the inside of the cabinet glue this into place and then when i put the edge banding on top of everything i'll use the flush trim bit and there's going to be an outer curve and an inner curve to this whole case so before adding the big round over to my actual project i glued up a test piece for where the filler piece was exactly the same thickness as the plywood actually it was slightly bigger and now i just trimmed it down so that it's nice and flush over here but from the inside to the outside it's all even and i did the same joinery as well and because i know that a lot of people aren't really so interested in adding huge 5 8 round overs to all their projects i wanted to see if this had a wider application on smaller roundovers like something like a quarter inch so i glued up just these this test miter right here miters is something that is a little bit difficult to get clean especially on plywood so i'm thinking that maybe this could be a really great way to like cover up how bad your miters are so um this glue up wasn't the best wasn't the worst whatever i wasn't really paying too much attention to it but what i'm going to do is i'm going to take a rabbeting bit and i'm going to make a quarter inch rabbet um in the end of this and then i'll glue in the filler piece after it was already glued up and then i'll add a quarter inch round over to that and see how that works i think that this is also going to add strength to a miter so um maybe i'll jump on these pieces and test them after i glue them up okay so obviously for a real project i would be aware of that situation oops all right finally i'm going to get to test the 5 8 round over on these pieces i'm going to take a little bit at a time so that the router is not taking off too much material so that looks really good i'm really happy with how that looks but if you look closely i'm not sure if this comes up on camera there's like a flat here before it gets around on both sides that's because this piece is the exact thickness as this plywood um so that's closer to three quarters and that's more than 5 8 which was that round over bit so not this whole piece over here doesn't get rounded over i'm sure that could be fixed with some sanding and everything to make it look like a smoother transition but i'm gonna go test out this bit on my actual project now just a quick sand to see what this is all gonna look like i think this looks really awesome and i'm super happy with the results compared to the test piece with the thicker filler strip the difference is really negligible so if i would have just used a filler piece that was the same thickness as the plywood and i didn't have to add in that inner chamfer in the corners it would have turned out really cool but when i see these two together this one looks a little bit chunkier to me than this one and it's that really just small little difference that i'm happy that i went the extra mile and added the inner chamfer to get the less material in the corner here so i'm really happy that i did that but it's totally not necessary to do this whole technique because this piece looks pretty cool too now i'm going to to test out that quarter inch round over on that other test piece [Music] i think that looks pretty cool now let's just get a better idea of what these are going to look like with some mineral spirits okay try to ignore that tear out situation look at it from this side i think that looks really cool that looks awesome now let's see how strong they are wow i'm really happy that i tested that out so adding a small filler strip to the corner of a miter does not strengthen it so if you want to add a round over a small round over to a mitered corner i highly suggest you adding something else to strengthen that miter lots of different ways to do that the way that i did it with the splines i think is plenty strong enough i stomped on this just as hard as i stomped on the one that broke and i think this is going to be plenty strong for my project i think that this is turning out really cool so far and i can't wait to show this build to you guys not only does this add strength and it looks really cool it's also going to be more durable so like plywood corners are really susceptible to damage especially with miters so adding this hardwood strip here is really going to make this piece super durable my kids are not going to be able to mess up this project so thank you guys so much for watching thanks to woodcraft for sponsoring this video and i'll see you on the next one which is going to be this build

Channel: 3x3Custom - Tamar

Views: 383,725

Rating: 4.9350085 out of 5

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Id: dQk_glgNAQk

Length: 17min 19sec (1039 seconds)

Published: Fri Oct 09 2020