2X4 roost.

If you can select a new, clean 2 x 4 of the length you wish there is no reason to do anything to it what so ever. If it is a old ratty looking thing, then perhaps some hand work would be required. Just pick a nice one, usually there are plenty to select from. Bumble Foot is not fun, but you won't be getting it from a new board, that you have chosen for your flock.

Best to you and your birds,

RJ
 
Mostly agree with RJ. Most 2x4's (or lumber in general) have edges that are already quite rounded enough. However, if you happen to get one with a square edge, with an actual 90-degree pointy corner, then I would round that off, just to be on the safe side.
 

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