Making a wood 'donut'
For my latest project I needed a 4" diameter circle with a 3" diameter hole in the middle out of 3/4" stock. The outside edges of the 'donut' or ring also needed a 1/4" round-over on the front and back.
Hole saws would have worked for a job like this but I don't have the correct sizes so I used the router. There's nothing special here, but if you're new to routing this might help you see one way of making something like this simply, safely, and relatively quickly.
The photos tell the story but here's what I did:
1. Drilled a 1/4" hole for the router circle guide pivot in the center of my 5.5" x 5.5" piece of cherry.
2. Drilled and counter sunk holes for screws in two corners, plus two within the inside diameter to attach the stock to a backup board. The screws keep the stock from slipping and turning, One set keeps the waste in place and the other set keeps the circle blank in place when the bit finally plunges through the 3/4" stock.
3. With the blank stock screwed to a backup board and the board clamped to the table I used a circle jig to cut the outside of the circle with 1/4" spiral bit making multiple passes.
4. Once the cut was finished I unscrewed and removed the outside waste.
5. With a 1/4" round-over bit in my trim router I rounded over the edge, unscrewed the circle, flipped it over, re-attached it to the backup board and rounded over the other edge.
6. Then, I unscrewed the circle blank from the backer, put some double-sided tape close to the outside of the final shape and reattached everything to the backer board. The tape holds the final donut in place when it breaks free from the center.
7. With the diameter reset on the circle jig I cut the inside diameter. Then it was a simple matter of unscrewing the center waste and pealing the donut off of the backer board.
As I said, nothing special here, just a simple no-hassle way to make what I needed.
Dragons slain. Damsels rescued. No reasonable request refused ... unless the dragon's really big. Simplicity is the ultimate sophistication. ~ Leonardo da Vinci You can't use up creativity. The more you use, the more you have. ~Oscar Wilde http://profhenrys.blogspot.com