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post #1 of 9 (permalink) Old 07-09-2011, 05:06 PM Thread Starter
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Default cutting a circular opening

So the reasoning for joining is my project is building a table for my Green Egg BBQ.
The table top will be made out of 5/4 cedar decking boards and I need to cut a
circle inside the table measuring 26 1/4 " . I want this to be a clean cut and neat
when finished . I figure a router circle jig would give a neat clean cut. So my
question is keeping in mind I have used a router once in my life!

Can a router be used to cut an opening of this size as well as able to cut an opening.
I have seen circle jigs used to cut circles and use the inside part. I need to use the router to cut this round opening. I hope this makes sense. Being a new member I
can not post links but if anyone wants some more info and is willing to help that
would be great . You can google Big Green Egg table plans and go to the website
under table plans. If anyone has any other suggestions it would be appreciated

Shawn
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post #2 of 9 (permalink) Old 07-09-2011, 05:47 PM
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Hi Shawn

The router will do a great job,you just need to make a simple cir. jig out of some scrap plywood.. for a one time thing.

http://texd.com/bge-table.pdf

==
Quote:
Originally Posted by Green Egger View Post
So the reasoning for joining is my project is building a table for my Green Egg BBQ.
The table top will be made out of 5/4 cedar decking boards and I need to cut a
circle inside the table measuring 26 1/4 " . I want this to be a clean cut and neat
when finished . I figure a router circle jig would give a neat clean cut. So my
question is keeping in mind I have used a router once in my life!

Can a router be used to cut an opening of this size as well as able to cut an opening.
I have seen circle jigs used to cut circles and use the inside part. I need to use the router to cut this round opening. I hope this makes sense. Being a new member I
can not post links but if anyone wants some more info and is willing to help that
would be great . You can google Big Green Egg table plans and go to the website
under table plans. If anyone has any other suggestions it would be appreciated

Shawn



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post #3 of 9 (permalink) Old 07-10-2011, 07:21 AM
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Quote:
Originally Posted by Green Egger View Post
So the reasoning for joining is my project is building a table for my Green Egg BBQ.
The table top will be made out of 5/4 cedar decking boards and I need to cut a
circle inside the table measuring 26 1/4 " . I want this to be a clean cut and neat
when finished . I figure a router circle jig would give a neat clean cut. So my
question is keeping in mind I have used a router once in my life!

Can a router be used to cut an opening of this size as well as able to cut an opening.
I have seen circle jigs used to cut circles and use the inside part. I need to use the router to cut this round opening. I hope this makes sense. Being a new member I
can not post links but if anyone wants some more info and is willing to help that
would be great . You can google Big Green Egg table plans and go to the website
under table plans. If anyone has any other suggestions it would be appreciated

Shawn
Make a larger version of this simple jig and rout in steps of no more than 1/4". The bit size isn't critical but 3/8" would be perfect.
Attached Files
File Type: zip A simple circle jig.zip (265.6 KB, 61 views)

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post #4 of 9 (permalink) Old 07-10-2011, 10:11 AM
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A simple board with a hole for the bit and a nail on the other end should work well for you.

==========

Quote:
Originally Posted by harrysin View Post
Make a larger version of this simple jig and rout in steps of no more than 1/4". The bit size isn't critical but 3/8" would be perfect.



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post #5 of 9 (permalink) Old 07-10-2011, 10:17 AM
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Isn't that what I suggested Bob?

Harry



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post #6 of 9 (permalink) Old 07-10-2011, 11:04 AM
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Shawn,
Hopefully your router is a plunge router, it can be done with a fixed base router but it's a lot simpler (and a tad safer) with a plunger.

(edit) You'll also need to figure a way to control the cutout as you finish the cut, ie. keeping everything from falling through the hole you just made.
If you cut it on a flat surface, remember that the router bit will cut into that surface. If you cut the hole after your table is complete tack, clamp, screw or whatever a couple of scraps to support the cutout.


Harry,
I can't open your zip files for some reason, anything special about them?

Last edited by TomE; 07-10-2011 at 11:13 AM.
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post #7 of 9 (permalink) Old 07-10-2011, 01:27 PM Thread Starter
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[QUOTE=TomE;242233]Shawn,
Hopefully your router is a plunge router, it can be done with a fixed base router but it's a lot simpler (and a tad safer) with a plunger.

(edit) You'll also need to figure a way to control the cutout as you finish the cut, ie. keeping everything from falling through the hole you just made.
If you cut it on a flat surface, remember that the router bit will cut into that surface. If you cut the hole after your table is complete tack, clamp, screw or whatever a couple of scraps to support the cutout.


I have access to an old fixed B & D router but are looking at purchasing a router for
this job and for other projects around the house. A plunge router would be way easier
of tackling this job.

Thanks for the idea of tacking the cutout . Nothing more fustrating than spending time cutting a board or an opening like this and have it destroyed and broken into
pieces making it useless.

Thanks as well to everyone else that has replied and responded so quickly !

Any other input anyone has will also be considered
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post #8 of 9 (permalink) Old 07-10-2011, 08:02 PM
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Here's a quick trammel arm I made to route a 60" tabletop. The router I used was a Porter Cable 690 with a 1/2" straight bit. No need for a template guide. I used a 1/4" piece of MDF cut to 48"L x 5-3/4"W. I drew a line down the middle for measurement (2-7/8") of different radius's. Drill a hole larger than your bit for clearance center of where you bit is located. Use the router plate for hole mounting locations & mount MDF trammel arm in it's place.

To route an outside circle I measure to the front side of the bit. For an inside radius I measure to the far side of the bit. I use a nail as a pivot point & locate it half the distance of radius needed. I routed from the bottom so nail hole from the pivot would not be seen or damage the top side. The tools for routing out circles are probably just laying around in your shop as scrap.
Attached Thumbnails
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Name:	Quick Trammel for circles 002.jpg
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Name:	Trammel 001.jpg
Views:	65
Size:	165.7 KB
ID:	44824  


James
Whittier, CA.

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post #9 of 9 (permalink) Old 07-11-2011, 04:54 PM
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how did it go then
any photos
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