Photo 5- Smooth the curves with a 1/2" drum sander in the drill press.

Once the waste areas are all cut out, disattach the two sides from each other and pull the nails. Chuck up a 1/2" drum sander in the drill press (photo 5) and sand the curves smooth (unless, unlike me, you are so good on the scroll saw that you don't need to!). These drum sanders are available from Rockler at the above link. Note that in a few spots the drum sander may contact the wood on both sides of the drum as it fits into tight spaces. On these spots go slowly and let the sander cut at its own speed. Use the roughest grit first, then follow up with a finer grit to smooth things up. If you don't have a drill press place the drum sander in a hand-held drill, or use 60 grit sandpaper and sand by hand.

Photo 6- Filing the tight spots.

The sander won't reach one spot on the pattern, that is around the central circle. This curved area and the straight edge across from it must be smoothed with a file or sandpaper (photo 6).

Photo 7- Cutting a slight bevel on the edges at the router table.

I beveled the edges of the pattern with a 45o bevel bit in the router table as in photo 7. You could also use a roundover bit,but be sure you set the bit in the table low enough so that the bearing contacts the edge of the wood. An alternative would be to round over the edges by hand with sandpaper. If you use a router bit, make the cuts fairly quickly to avoid any dwelling which will cause router burn. Keep your fingers away from the bit.