Enlarge a completed cut out circle? - Router Forums
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post #1 of 24 (permalink) Old 02-22-2020, 04:49 AM Thread Starter
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Default Enlarge a completed cut out circle?

Now that I've finished my circle project, I ran into a gotcha...

Once I cut out the circle, it wasn't large enough by just a hair and I needed to enlarge the circle - about 1/4".

But, since the center was cut out, I couldn't figure out how to enlarge it with the router without doing it free hand.

I tried and almost really messed it up since I could not control the router around the circle, so I switched to my jig saw and did the best I could.

Is there (there must be) some technique or jig for enlarging a hole once it's been cut out?

Thanks as always in advance
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post #2 of 24 (permalink) Old 02-22-2020, 06:56 AM
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Use a straight bit, with a guide bearing - then swap out the bearing with one where the radius of the bearing is 1/4 inch smaller.

so the first time you cut a rabbet.

then afterwards you just use a trim bit where the bearing and the bit are the same.
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post #3 of 24 (permalink) Old 02-22-2020, 07:07 AM
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I would cut another circle out of a piece of material that would fit tightly inside the hole you have now ,thus providing a surface to secure to .

Or you can cut a bigger hole in another piece of material and secure it on top of your hole to act as a guide for a flush mount bit on your router and remove the excess material .

Is this a subwoofer box? I always do a test hole on another piece of material first. Once I get it perfect I save the plug for future woofers
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post #4 of 24 (permalink) Old 02-22-2020, 07:54 AM
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I would place another piece of wood under the hole and use that piece of wood to attach the trammel to. You might not be able to get the new circle in the exact location but as long as the bit was able to cut on all sides the circle would be round.
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post #5 of 24 (permalink) Old 02-22-2020, 08:01 AM
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Quote:
Originally Posted by newbie2wood View Post

Is there (there must be) some technique or jig for enlarging a hole once it's been cut out?
cut a bearing guided rabbet to desired depth...
switch to a bearing guided straight bit...
follow the inset wall of the rabbet w/ the straight finish to the size you need...

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post #6 of 24 (permalink) Old 02-22-2020, 09:22 AM
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Since you may have boogered up the shape of the original hole, I would agree with tacking your workpiece to a sacrificial board. Then take the center piece you cut out originally and tacking that to the sacrificial board, centered as best as you can. Use your circle cutting jig again.

You'll get a better looking circle, more practice with the jig, and less frustration.
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post #7 of 24 (permalink) Old 02-22-2020, 09:52 AM
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Quote:
Originally Posted by lowracer View Post
Use a straight bit, with a guide bearing - then swap out the bearing with one where the radius of the bearing is 1/4 inch smaller.

so the first time you cut a rabbet.

then afterwards you just use a trim bit where the bearing and the bit are the same.
Wont that remove 1/2"? A 1/4" all round.

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post #8 of 24 (permalink) Old 02-22-2020, 10:21 AM
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Quote:
Originally Posted by harrysin View Post
Wont that remove 1/2"? A 1/4" all round.
True, but we don't know if the OP was referring to 1/4" radius or diameter.
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post #9 of 24 (permalink) Old 02-22-2020, 10:39 AM
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If you still have the sacrificial backing board and it has both the center hole in it and the outline of the original circle showing (provided you cut into it slightly when you did the original) you can line the finished hole with that outline and then drill a piece of ply the same size and pin through it into the original center hole and simply cut a slightly larger circle. You'll be set up exactly the same the second time around.
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post #10 of 24 (permalink) Old 02-22-2020, 12:29 PM
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I just use the new Kreg Hole Stretcher.

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