Looking for a jig to make flat curved pieces out of 1/8” plywood - Router Forums
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post #1 of 41 (permalink) Old 01-13-2012, 03:17 PM Thread Starter
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Default Looking for a jig to make flat curved pieces out of 1/8” plywood

Hi guys, it’s been awhile since I’ve used my router, so I haven’t been on for awhile.

I need help to cut 28 curved pieces of 1/8” thick plywood and I thought I could just use my RotoZip Saw with and extension to the RotoZip Circle Cutter attachment to quickly make them. Well that turned out to be a disaster there is so much play in the Circle Cutter attachment that it takes too much to get a perfect radius.



So now this idea is going in the garbage and I’m thinking of using my RIDGID R2401 - Trim Router with a 1/8 Single Flute Straight Bit and a wide piece of plywood for the Circle Cutter attachment so that it will not rock.

I took the base off the Trim Router with the 4 screws which are too short to attach to a piece of ½” plywood and after looking through my screw assortment I realize that I don’t have one that fits and I don’t even know what size it is. Anyway I need to go to the store to buy a bit and I’ll see if I can pick up the correct screws.

So now I’m wondering if there is a better way to do this. I thought about making a jig to run a router around inside, but it would be gigantic and hard to handle. I don’t want to use a jig saw because it tears up the 1/8" plywood too much.

Any ideas?

Each piece is a 1 ½” wide ¼ circle with 15” inside radius and there is a 7” straight leg extending out from one end of the circle.


Last edited by JohnnyB60; 01-13-2012 at 04:18 PM.
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post #2 of 41 (permalink) Old 01-13-2012, 04:04 PM
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Hi Johnny.
You can make a quick trammel for your router. Use 1/4" mdf & you can use the same screws to hold your base plate on. Here is some pictures of one I made for a PC router. This jig is set up to use a 1/2" straight bit. You can use a smaller bit if you wish.

I rip the width to the same size as the router for easy alignment. The base plate can be a used as template to line up mounting of the router. Ripping the mdf to the width of the base allows lining up between the 3 sides of one end to center on trammel. After trammel is ripped to width I like to draw a center line down the middle for measurements. Also draw a cross line at center to drill for bit. I also draw a line on both sides of bit to measure for inside & outside radius before I drill center hole. A 1/2" bit these lines will be 1/4" of each side of center line.

For a pivot pin I use anything from a finish nail to a 8p double head. Marking the lines ahead of time helps with setup. It's hard to mark for your cuts after you drill center hole. By doing this before you drill for bit you can measure much more accurately as your layout lines are already there to measure off of. The far side of the bit is for inside radius & the near side is for outside radius. You can see how this is marked on my trammel. Using your 1/8" bit your lines off center of the bit will be 1/16" each side of center. I prefer a 1/2" bit but would use at least a 1/4" bit, but don't go to fast or you will snap that 1/8" bit.
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James
Whittier, CA.

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Last edited by jlord; 01-13-2012 at 04:11 PM.
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post #3 of 41 (permalink) Old 01-13-2012, 04:27 PM
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You can also make one as a template out of 1/4" mdf then double stick tape & flush trim them out. Or use template on top & use a pattern bit.

James
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post #4 of 41 (permalink) Old 01-13-2012, 04:31 PM Thread Starter
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Thanks James, that’s kind of what I had in mind. I’m not sure I have any ¼” MDF in stock, but maybe I can recess out ¼” out of some ½”. I need to make two cuts for each piece. one for the outside cut and then the inside.

I took this silly RotoZip Circle Cuter attachment apart and I can see why it’s so flimsy and I was thinking that if I could find a thick gasket or washer that will fit between the pieces, I just might be able to tighten it up.

I'm a little worried about the template because I have so many to do, I'm might screw some up.
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post #5 of 41 (permalink) Old 01-13-2012, 04:42 PM
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1/4" mdf can be bought in quarter sheets at home depot. It should only be a few dollars. Or even some 1/4" bead board made from mdf. Put bead board side down. MDF is good template material as it machines easy & has no grain to cause bits to wander when drilling.

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post #6 of 41 (permalink) Old 01-13-2012, 05:29 PM
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+1 for the template idea. Easy peasy.
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post #7 of 41 (permalink) Old 01-13-2012, 06:28 PM Thread Starter
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The pattern bit would probably be the best idea because I can do the entire piece in one shot. Right now I have to cut the outside curve, stop to change pivot points for cutting the inside curve then I have use a straight edge to cut the straight sections. I’m going to look into the pattern idea, but I want to have the pattern above the plywood.

The only reason I started with RotoZip tool was the 1/8” cutting bit. The smallest Pattern bit I have is ½” and I don’t want to remove that much material. I wonder what the smallest pattern bit is available. If I can find a 1/8” bit with a ¼” shank, that would be great. I also have a ¼” Flush Trim Bit without a bearing, but I would have to fasten the plywood to the top of my pattern and run bit through except that I don’t like how it heats up and burns the pattern.
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post #8 of 41 (permalink) Old 01-13-2012, 06:40 PM
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Hi




"It's fine to disagree with other members as long as you respect their opinions"

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Last edited by bobj3; 01-14-2012 at 10:57 PM.
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post #9 of 41 (permalink) Old 01-13-2012, 07:17 PM Thread Starter
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Quote:
Originally Posted by bobj3 View Post
Hi

Your RotoZip will do a fine job, you can make a base plate for it or just use your 1/2" thick stock and put in a pocket for it to sit in, your RotoZip should take on 1/4" router bits, so you can pickup a pattern bit or trim skew bit and it will do the job you want to just fine..

If you make a base for your RotoZip just put in two holes so you screw it down to your 1/2" thick stock.

So you can use it for a cir jig quick and easy.. =
Now that’s an Idea. I actually looked on line earlier to see if I could buy an extra base so I could super glue it onto something.

You gave me an idea though. I wonder if I take the sheet metal part off and fasten the rest with the round locknut to a piece of Plexiglas.

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post #10 of 41 (permalink) Old 01-13-2012, 07:28 PM
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You can get a pattern bit with the bearing on the shank at Home Depot. You would have a larger selection at a Rockler or a place similar. If you intend on using An 1/8" bit you will have to make the template narrower to compensate for the difference in a bearing or template guide. The easiest would be a 1/2" bit & bearing so you can make template exact size. But it does use a little more material.

James
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