To speed up the cutting and smoothing of each, I used my last router and a knockoff "Work Mate" and fashioned a Pin Router.
I make a template of each shape out of 3/4" plywood and hammer 3, 1" brads through the back so that they protrude about 1/4". First, I use the template to quickly outline the shape onto primed HDU.
Next I bandsaw off the waist....staying way off the line.
Next, I press the template (Nails Down) onto the HDU. The bearing of the router bit rides on the plywood template and the shape is cut perfectly.
Next, I step over to to my other router table and cut the cove.
I then break the corners with some 220 paper and I'm off to prime and paint. I can now go from primed sheet to ready to carve in less than 25 minutes. (Production Time)
Big improvement!
Hope this is helpfull to someone.
Edited to add that this isn't a true pin router. A pin router is a different setup but works basically the same way. "Trim Router" is probly a better term.
Joe
Denver Chapter of the Letterheads