Corner rounder

How about buying a radial template like the architechts use, mark them and jig saw them then finish with some light sanding? Just an idea

 

How many at a time ??

We many times just sand them with a belt sander or our disc sander. Up to .080 aluminum sands like nothing and fast, too.

If you want to cut down on time, grind them first and then sand.

 

It sounds like you need to ask your clients to stop running your business!
If this guy is ordering enough of these signs on a regular basis, it's time to talk with thim and negotiate to get him to commit to a contract quantity and price. This will afford you the opportunity to either buy the corner rounder, be able to stock what you need.
I use tin snips and a file on .080" aluminum. A belt sander would work too. If the design has a border, like a No Parking sign, I design the radius corner into the design, apply the vinyl and use that as my template.

Checkers

 

I use a Delta 1" upright belt sander. Works fine for me.

 

Hey
Try this link. I deal with this people and I must say that I am very happy with all the things I own from them. And they make most of the them in- house in York Pa. Wonderful people to deal with, have met them at shows.

http://www.accucutter.com/Cmate%20080.htm

 

The accucutter is workhorse. The inital investment, like anything else, takes away from profit - but it lasts forever AND will make the work soooooo much easier.

GitRdone - noticed that you are into "birds". Don't know if you do any trap, but it is the difference between hand-tossing the clays or using the machine.

 

http://www.signsplusbanners.com/catalog_c102567.html

 

Like maddmd mentioned Accucutter is a very good tool to have around the shop. Initially a bit costly but it will soon pay for itself. We round corners on aluminum, komatex, coroplast, etc. just about anything that will fit into the die.

 

I also had a need for special sizes and hated the cornering process. The Accutter is sure spendy and I held off for a long time. Finally broke down and spent the big $$. I have to tell you, it's one of the best investments I've made. I also searched high and low to find and alternative with no luck.