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I've several pieces of 1/4" plywood that have a 3/4 radius on two of the corners.  I want to now round over the edges with 1/16" router bit but there's too much space between the cutting edge and the bearing to make a pass on the other side of the material, and  because of the radius on the corners there's no way to keep the edges otherwise aligned.

Any suggestions?

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I've not had a problem, using this style bit.

(Very small gap between cutter and bearing).

Freud 34-100 1/16-Inch Radius Rounding Over Bit with 1/4-Inch Shank

Tape, (douple stick tape), an identical shaped piece to the underside of the workpiece you're machining.

Route the edge of the workpiece, flip the two bonded pieces and machine the second one.

Separate the two peices, and proceed with the remaining workpieces.

Option(s):

a. make a template of 1/4" hardboard---same shape as the workpiece.

The bearing to ride on the template edge.

b. apply a 1/4-1/2" thick, wood material, flush with the workpiece edge on the underside.

Thanks for the help.  I did go that route but now I have to make more of the pieces and it's not easy to reproduce multiples that way.  I was looking for a means to bring the bearing down to the near edge of the carbide.

Attachments:

Might look for a bull-nose bit and run it against a fence.

Alternate tools:
a. block plane,

b. sander,

c. fine rasp,

d. scraper

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