SgtPelph

Several months ago I spotted a Marble Solitare game project in one of the wood working magazines. My first experience cutting a large circle was not a positive endeavor. I posted here for advice and received many helpful tips and links to videos. I quickly realized that my skill level and available tool resources did not lend itself to cutting circles. I moved on with the thought that someday I would revisit the project when my skill level increased and I had more tools to work with. Here comes the question: I keep seeing a circle cutting router jig (Rockler October catalog page 39). Does this jig coupled with a plunge router actually cut circles? If so which router bit is used? How thick can the stock be?

Hope to be going in circles soon...

Leo G

All you need is a pc of plywood with a nail in one end and a hole in the other. Attach the router to the plywood with the hole in it (6" wide plywood, 1/2" thick with a 2" hole in the center). Then measure from the 1/2" shank, 1/2" straight bit to the nail whatever radius you plan on cutting to. Bang the nail into the pc you are cutting and then make 1/8" passes with the router until you are just about through (.005-.010"). Remove the jig and cut the remaining with a jigsaw. Then flush cut or sand the onion skin off. Hopefully you can have a center hole showing in the pc, or put it on the backside where it won't show.

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Measure Twice Cut Once -- It's a lot easier to cut more off then it is to cut MORON.
TGIF just means two more working days until Monday http://lrgwood.com

Tony B

I pretty much do what Leo says except I eventually go all of the way through with the plunge router.

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Tony B

http://www.thetexaswoodworks.com

BHOFM

I just find something the right size and double back
tape it to the bottom side and use my laminate bit.

I did some wheels and had an old pizza pan that
was just right. I taped it, bottom side up, to the
ply after roughing it out with the bandsaw. I did
three, 3/4" and then glued them together to make
a wide wheel.

I let the bearing run on the lip to keep the bit
away from the metal pan.

Finding the center is a trick when you do this.

I made a wheel barrow for a flower shop, wish I
had a picture of it. It was made entirely of 3/4"
ply. The axle was a 1" oak dowel.

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