My New Router Circle Jig V 2.0 - Router Forums
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post #1 of 34 (permalink) Old 06-24-2012, 05:50 PM Thread Starter
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Default My New Router Circle Jig V 2.0

Recently, I just completed my new router fence version 2.0 (Refer to "My New Router Fence V 2.0" in the Table Mounted Section) and turned my attention to designing a new router table. I realized in short order that I will need to cut precision circle holes and dados to accomplish the design features I want in my new router table.

Viola'... my new router jig for cutting circle holes from 1.5-inches to 6-feet in diameter - yes, that's right 6-feet in diameter! My new jig has a 3-foot radius reach. Not that I would ever cut a 6-foot diameter hole but those large arcing arches will be a snap now.

The last pic is the jig's maiden cut... 4-inches in diameter according to the micrometer. I kept the platform wide to rest my coffee cup on during cuts.
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post #2 of 34 (permalink) Old 06-24-2012, 07:16 PM
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Circle jigs are always handy around the shop....

Does you sliding arm have a beveled edge? How do you set the distance from the bit to the 1/4" post?

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post #3 of 34 (permalink) Old 06-25-2012, 01:58 AM Thread Starter
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Thanks James for the interest.

No bevel on the sliding arm, just a right angle cut with a matching dado on the under side of the jig base. I routed a "T" slot in the top of the sliding arm and inserted a "T" Bolt that is used as a means to hold tight the dimension from the bit to the pivot pin. If you look at the third pic above, you'll see the threaded end of the "T" bolt protruding through the jig base. For the time being, I put a standard 1/4-20 nut with washers to secure the "T" bolt, but I will retro-fit it with a five star knob after my next visit to Rockler. I used the circle jig today to cut a circular plexi-glass router table base plate and corresponding circular dado. The jig performed quite nicely and made short work of the match up work. I'll post pics of the finished router table top once I complete that task.
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post #4 of 34 (permalink) Old 06-26-2012, 01:02 AM Thread Starter
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Default Circle Jig Performance

Lovin' my new circle jig!

It made short and precise work out of cutting the plexiglass ring (router base plate) and corresponding circular dado in the router table top. The new router base plate fit like a glove in the circular dado.
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post #5 of 34 (permalink) Old 07-01-2012, 03:02 AM
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Hi, Keith.

Can you show to us how does your circle jig work?

Thank you in advance.

We, woodworkers are everywhere!!!
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post #6 of 34 (permalink) Old 07-07-2012, 11:19 PM Thread Starter
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Default My New Circle Jig V 2.0

Alexis:

Okay, probably the best way to show you how this circle jig works is through a real life example. My mission was to cut an access hole in a portable table top so that I could attach my new router table top and fence.

Here are the steps, you can follow along with the enclosed photos:
1) Locate the general site of your target access hole;
2) Measure the radius of the desired hole using a compass;
3) Attach the router to the circle jig;
4) Use the compass to profile the distance between the pivot stud (on the circle jig) and the outside diameter of the router bit;
5) Tighten the "T" bolt on the circle jig to secure the adjustment bar that secures distance between the pivot stud and router bit;
6) Verify the location of the desired access hole in relation to the new router table top;
7) Use the compass to superimpose the desired access hole dimension on the target table top;
8) Drill a pilot hole on the table top to accept the pivot stud on the circle jig;
9) Insert the pivot stud in the pilot hole with the router in operation;
10) Rotate the circle jig counterclockwise with the router in operation; and
11) Continue the counterclockwise rotation until the cut is complete.

Viola'... the new access hole allows the router, new router table and fence to fit exactly as intended.
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post #7 of 34 (permalink) Old 07-07-2012, 11:23 PM Thread Starter
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Default My New Circle Jig V 2.0

Here are the other photos to follow along
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post #8 of 34 (permalink) Old 07-07-2012, 11:26 PM Thread Starter
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Default My New Circle Jig V 2.0

The rest of the photos
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post #9 of 34 (permalink) Old 07-08-2012, 12:41 AM
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Thanks Keith,

Those pictures gave a better answer to my earlier question. I can see retaining bolt is held in the movable arm in a T-slot, so no bevel required...

James
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post #10 of 34 (permalink) Old 07-08-2012, 12:51 AM
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that is a great jig, and it looks like it can do very small circles just as well as very large ones. thanks for sharing it!

is that a 3/4" thick piece with a 1/2" piece for the slider?

Last edited by Chris Curl; 07-08-2012 at 12:54 AM.
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