My last use of the circle cutter was to make the blast gates for my DC. They only had to cut 3/4". If I was cutting very fat or more than one I'd be looking for a different method. But if you want to make the circle cutter work it should be possible.
If you're positive you are at 90, not 89.99 or 90.01, then you might try tweaking the cutting bit - make sure it is even in thickness or better - tapering so the top is thinner than the bottom - if any part is thicker than the cutting point then it will jam. You can also try relieving the back two edges of the bit so they don't rub on the sides. It should be scary sharp since it is going to be sharpened like a small chisel and basically cuts like a motorized plow plane.
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Last edited by joesbucketorust; 04-05-2012 at 09:41 AM.
Reason: fixed a typo