I, personally, think the spade bit is the best idea out there....but much like Chris, I grind them down wrong.

You know, there must be some sort of use for a rounded off spade bit in the industry.....why can't someone design and produce one?? That would be ideal. Keep the cutting edge on the entire side and perfectly round. There must be a way and I'm on a mission ;)

Has anyone tried ball end mills?
They come already ground with the radius on it just like your talking about bob. The only problem is that are expensive, but not much more than a router bit would cost, or buying a dremel - mine met it's maker many moons ago :( - and the bits.
I've never used them on wood, but i don't think you would have any problems with softer woods like cedar. They might burn out, but if you can't get the angle right by hand - which is difficult, but possible - this may be a good way to go.
I don't know any stores you can them at. If you know anyone who works in any 'craftsman' type trade they can get it through MSC. Or try Ebay or any search engine for 'ball end mills'. Don't buy one too long, you wont need more than 3/4"

Some great ideas :kewl: Thanks for sharing.

Have not tried those end mills on wood. I have a couple of sets. Might have to give it a go. You can get them from grizzly.com and a number of other places online. Amazon may even have them.

Jigman