How to Cut a Bar Top for Radius Corner Installation

Sometimes cutting corners is a good thing! Here at Hardwoods Incorporated, we offer a wide selection of radius bar rail corners and curved bar rails to navigate those tricky ends. These provide safer corners and a more attractive rounded look to your bar rail. Nothing else will give your bar or counter-top a quality custom appearance without the exorbitant cost!

Our radius corners are user-friendly and come pre-trimmed ready for installation. All you have to do is follow these simple guidelines to preparing the bar top prior to installation.

Bar Top Cutting Instructions

The 6″ and 12″ radius is measured to the first notch of the bar rail. This is the measurement you will use to cut the bar top itself. The radius for the second notch will be used when cutting the sub top.

BR 475 6" radius profile

BR 475 12" radius profile

Step 1:

Draw the following radii on a piece of cardboard as shown. Make sure the bottom left corner is square (90 degrees) before drawing the radii.

For cutting a 90° corner:

6-inch-radius-cutting-instructions-90-degrees
12-inch-radius-cutting-instructions-90-degrees

For cutting a 135° corner:

6-inch-radius-cutting-instructions-135-deg
12-inch-radius-cutting-instructions-135-degrees

Step 2:

First cut along the 7-9/16″ or 13-6/16″ radius line on the cardboard and use it to mark the sub-top with a pencil. Second cut out the 6″  or 12″ radius and use it to mark your main bar top where the radius corner is to be installed.

*For the BR158 both the main and sub-tops are cut using the 6″ template.

For cutting a 90° corner:

6-inch-radius-cutting-instructions-90-degrees

12-inch-radius-cutting-instructions-90-degrees

For cutting a 135° corner:

6-inch-radius-cutting-instructions-135-degrees

12-inch-radius-cutting-instructions-135-degrees

Step 3:

Use a jig saw to carefully cut your main and sub-bar-top closely following the pencil mark. Afterward you can sand the radius cuts to smooth out any major imperfections however where reasonable accuracy is necessary perfection here is not as the bar rail covers both the main and sub-top.