Message #62300

[Maver!ck]

I use a router to cut the initial shape.  I have used a larger band-saw.(tough on bandsaw blades though)
Then i use the bench grinder to round off edges.  You might consider something a little thicker than 5/16.  
I've used up to 3/8 material and still have them break on me, that is why i moved up to 1/2 inch.  
Also, consider this... the longer the stick and the thinner it is, the easier you can break it.  You don't want it too short though.
I like the happy medium of just under 12 inches long, 1/2" thick and about 2 1/2" wide.
Not real easy to break them with these dimensions and made from the right material.

Maver!ck