On 26 Jun, 13:31, sailor wrote:
How about just cutting the whole slot with a jig saw?
Or for a cleaner cut, how about making a simple jig and use the
router?

I think I would rough cut with the jig saw, then use the router and
jig.

Let us know what you do.

I was thinking that a 1.25" diameter curve in 3/4 ply might be a
little tough to cut consistantly with a jigsaw. (I don't do a lot of
jigsaw work) Since there are 9 slots spaced evenly along a 31" length
of stock, if I don't get the depth or width fairly consistant, it will
be very noticable. A hole saw on the drill press makes it real easy to
get the spacing and size consistant.

Anyway, I'll be testing my prototype at a game tonight and if it
performs as expected, I'll be making more this weekend. I'm leaning
towards a short auger style bit - under $15 at HD which should get me
through this project. After all the slots are cut, I'll round them all
over with my router. so a little tearout on the bottom won't be
problem.

Thanks for all the suggestions.