How to make a circle (no center hole) - Router Forums
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post #1 of 16 (permalink) Old 10-11-2012, 02:43 AM Thread Starter
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Default How to make a circle (no center hole)

I have a small task: make a cover of an access hole in my kayak, since I lost the original rubber cover. My idea is to make it from clear plastic, since the hole rim has threads for screws.

I think the router could do the job.

Finding a circle jig is not really an issue: just drill a hole and rotate tool around it. But.. since this is for water-use, drilling a hole is a bad idea.

So any nice tips on how to avoid this center hole ? I would like to have a perfect circle at the end.

FYI: my workshop is very small, and I only have a std. plunge type router for the job.
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post #2 of 16 (permalink) Old 10-11-2012, 02:51 AM
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Torben; how about simply making a template then using it as a pattern? A ctr. hole in the template won't matter.
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post #3 of 16 (permalink) Old 10-11-2012, 03:26 AM
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Yep, a pattern double sided taped down.

Under construction, always.
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post #4 of 16 (permalink) Old 10-11-2012, 07:10 AM
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You don't necessarily need a hole all the way through to use a circle jig, if the piece is thick enough to accommodate a blind hole. If not the pattern idea sounds nice and simple.
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post #5 of 16 (permalink) Old 10-11-2012, 07:43 AM
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hi,have you tried double sticky sided tape make a template stick it on the plastic and run the router round and peel it off dave northyorks uk
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post #6 of 16 (permalink) Old 10-11-2012, 08:30 AM
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use a hole saw and cut a hole in a piece of 3/4 in stock. Then take the drill bit out of the hole saw and use the piece you cut out of wood as a guide. Place the piece on the part you want to cut so that the bitless (is this a word?) hole saw won't wander around.
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post #7 of 16 (permalink) Old 10-11-2012, 09:19 AM
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Isn't Guy Fawkes coming up soon?

Just thinking in case you don't get the circle cut :-)
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post #8 of 16 (permalink) Old 10-11-2012, 09:48 AM
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Quote:
Originally Posted by myicq View Post
I have a small task: make a cover of an access hole in my kayak, since I lost the original rubber cover. My idea is to make it from clear plastic, since the hole rim has threads for screws.

I think the router could do the job.

Finding a circle jig is not really an issue: just drill a hole and rotate tool around it. But.. since this is for water-use, drilling a hole is a bad idea.

So any nice tips on how to avoid this center hole ? I would like to have a perfect circle at the end.

FYI: my workshop is very small, and I only have a std. plunge type router for the job.
Rout a hole in a piece of MDF etc using a router circle jig then sit this on top of your material and, using a template guide and straight bit route your disk.
To calculate the diameter of the hole in the template the simple formula is:
template guide dia. - bit dia. + size of wanted disk.
Suppose that you require a 6" disk and decide to use a 1" template guide and a 1/4" bit, then: 1"-1/4"+6"=6 3/4" hole in the template. It really is that simple.
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post #9 of 16 (permalink) Old 10-11-2012, 11:21 AM
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You can always use a template to rout a circle, but would a hole really be such a problem? If the lid is going to be solid, why not use the hole to secure a handle? or a rod-holder? or a cleat?
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post #10 of 16 (permalink) Old 10-11-2012, 12:03 PM
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Take the easy way out and use a suction cup that has a long hook that can be formed to a pin and circle away.
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