cutting smaller circles...Help.

[wood-n-things]

I need some help with cutting smaller circles. I'm stack cutting 1/4" ply for Christmas ornaments for Project Rudolph and I've cut several that are circles with a cutout in the interior but I am spending way too much time in cleaning up (sanding) the circle to make it symmetrical after cutting the circle with my scroll saw...They aren't horrible but I want to do a nice job.

I have tried my hole saws but they are not the answer, they are too aggressive and splinter the wood too bad.
I have tried my circle cutting attachment for my drill press but it does not cut 5" size.
I tried the circle cutting jig I made but cannot stack cut them they are just one at a time.

Hints tips...or just don't make round ornaments...shrug


Almost forgot..not all the ornament patterns I have in my folders have a cutout that will allow for a hole in the center of the ornament....so I have made a few candy canes, and a few angels, and a few christmas trees, to circumvent that problem.

[minowevie]

Mike, I use brad point drill bits to cut small circles. they are right on, and clean. your friend Evie

[wood-n-things]

I understand Evie but I'm referring to the outside diameter of the ornament being 5" around.....Thanks for your response though.

[Gill]

The best tool for this job is undoubtedly a router fixed to a trammel bar. Using a home-made jig made out of MDF, I've been able to rout perfect discs measuring 18mm (3/4") external diameter. This is the jig viewed from underneath:



Simply attach the material you wish to rout to a sacrificial board using double-sided tape, sink the small pin into the center, and spin the router around the pin .

[Arcy]

For the patterns that will allow a pinhole in the center, you can clean up the outside of the circle after the fact by pinning it in place and rotating at a constant radius from your sander.

--Rob

[wood-n-things]

Rob,
I tried your technique and although a little time consuming it does the trick for onesies thanks.

Gill,
as soon as I can visualize this a little better I may give that a try..I understand the concept but having a brain fart at this moment...as to how to attach my router to the trammel.

[minowevie]

Oh ok, I thought you said, HEHE> a small circle. in my mind that is really small. I would agree with Rob. that is the best way. out side of practice. when I can sand it down to the right size, it works for me. it is the end product that I am trying to do. your friend Evie

[Wood Dog]

Mike have you seen this video on youtube...using table saw to cut circles.
YouTube - Cut a Circle on a Table Saw

[Gill]

Hi Mike

Think of my trammel jig as a false router base. You should be able to see two recessed holes in the underside of the jig - these are simply to allow you to screw the base of your router in place. The cutter protrudes through the hole and (because the edge of the cutter is always the same distance from the pin) cuts a perfect circle when it is spun on the pin.

That said, if you have a sanding station then Rob's idea is neat. In fact, earlier today I used that very technique to trim the edges of a coaster I had cut by simply spinning the coaster underneath the finger which was holding it in place! It's a design I lifted off a beer bottle label (my hubby's favorite brew ) but since it's just a one-off, I don't think I'll be pursued for breach of the trademark.



The beer is called "Abbot's Ale" - can you see the resemblance to an abbot? I've now received 'orders' to make similar coasters for Bateman's XXXB and Black Sheep Riggwelter! It just goes to show that you can get ideas from the strangest sources.

[wood-n-things]

Thanks Evie.

WD I have seen that you tube video thanks.

Gill...I think I got it now thanks. Nice job on the coaster btw.