I need to create a non-standard shape of thick plywood (1+") for an extension to a kitchen island. Shape is something like this:
... the size is roughly 3ft-square, and the inside and outside corners have radius 1", though I might settle for a bit more **. I have some preliminary thoughts about how to do it. I'd appreciate commentary on these and additional suggestions.
I'll create the material, before marking or cutting, by glueing two 3/4" sheets of plywood with Liquid Nails and screwing with 1-1/4" screws.
For marking, I could draw directly on the plywood using pencil. Or I could draw on a large sheet of paper (or print, if I had a big enough printer, which I don't) to get it right and somehow transfer that to the plywood. Anyhow, I can use trial & error, an eraser, and both sides of the double-thick plywood, to get it right.
Cutting will be the crux. I can imagine first cutting out circles where the inside corners are, using a hole saw; and then roughing out the rest (with the outside corners squared) with a circular and guide fences, or a table saw; and finally, shaping the outside corners with a jigsaw. Simpler and better, if I knew where to go, would be to take it to some shop where they cut it for me, perhaps using a band saw.
** As background, though I've worked this part out with a temporary piece: the flared out part will sit on an existing kneewall at the end of a lower countertop and it'll be cantilevered out from there with a diagonal brace back to the kneewall.