Originally Posted by Pablino
I use a hole saw to cut out 2" holes out of 3/4" cedar boards, what is the safest to trim the 2" round plugs edges with a round over- bit, I use a table mounted router. The plugs are used for wheels on wood toys, I need all the help I can get, the toys are given to the childern homes for battered and forgotten kids.
Before I head over East
Looking for an alternative method that is safe.
1. You can first cut the shapes with your hole saw if you wish making them a little larger than you require or simply cut small squares.
2. Drill a hole centrally in the square blocks
3. Drill a smaller plug that can be attached to the square block and also to a sacrificial board. This is done with a countersunk metal threaded screw which will hold the material secure. Calculations are required as to what guide and cutter is to be used.calculations are required as to what guide and cutter is to be used
Sorry about the double dipping
4. With an extended rounding over cutter it is possible to rout the shape and apply the rounding over required. Router is used on the plunge mode. Make a simple router support or use a set of skis to support the router
5. The wheel can now be returned over and the rounding over can be repeated. A little extra work in preparation but it will beTotally Safe
I may have to supply some drawings if you cannot follow the method described but I will be away for a few days and not at the computer in that time.