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circle-router-jig-array With the fence still in place, rout the smaller slot the in the same way as the first one. I kinda wondered that too Thanks for learning circle router jig array my circle router jig! A while back I built a jig that would allow you to cut a circle with your router. Now the baseplate can be removed from the router, and the router can be installed in the jig using the baseplate screws.

Drill holes for the mounting screws, making them just a little bigger than the diameter of your screws. Flip the base over, and using the holes as a guide, trace the baseplate on this side too.

Choose which side you want to moun the router on, and chamfer the mounting holes on the opposite side. You want the chamfers just deep enough that the screws will sit beneath the surace. Drill or rout out the center hole.

It just has to be slightly bigger than the largest router bit you might use. A hole saw is probably best for larger holes, but I used a twist bit, and it caught and made a pretty messy hole. It won't really effect anything other than aesthetics, but next time I'll take the time to get the correct bit out.

I did clean up the hole a little with the router later. The mounting screws are most likely much too short to reach all the way through the base material. We could buy longer mounting screws, but unless you have a set of really long router bits, the thickness of the base may limit the depth of cuts you can make with the finished jig.

To solve both problems, I reccomend routing a recess in the base for the router to sit down in. After clamping the base to a work surface with the router mounting side up, rout out the baseplate area, using the line you traced as a guide.

It's easiest to start at the center and work around the the hole clockwise, sneaking up on the final size with a few light passes. Now the baseplate can be removed from the router, and the router can be installed in the jig using the baseplate screws. Make sure all the screws sit flush with the bottom suface of the jig so that they won't catch on anything.

While the easiest thing to do is buy a t-handle or star handle for jigs, but I'm too cheap to do that, so I make my own.

It takes a piece of scrap wood, a t-nut which costs just a few cents, and takes just a few minutes to make. I make them in bulk to use in all of my jigs, and I won't go into the process here.

It's easy enough to simply cut out a shape you like, drill a hole in the center to accept the t-nut, and hammer it in place. I didn't have any threaded rod, so I just cut the head off of a 3" bolt.

Screw the nut onto the center of the threaded rod, and then place the washer on. Slide the portion above the washer up Make Router Circle Jig throught the slot in the base, and then screw the handle on to the top. Alternatively, if you have access to a metal lathe as I do, you can cut the threads off one end of the threaded rod, making a smooth post of a specific size.

That way you can use a drill bit that matches the specific size, and always be sure to have a nice tight fit. The threaded rod with an appropriate sized drill bit should work well enough for most applications though. This step is entirely optional, but I thought it might make it slightly easier to use.

The base had quite a bit of uneccesary wood, so I decided to cut it off, and round the corners. I also slightly beveled the edges on the bottom side with some sandpaper so that they wouldn't catch on anything as they slide around the circle.

The first step to using it is setting the post height. Measure the thickness of the material you'll be cutting a circle in. Adjust the nut on the post so that it sticks out slightly less than the material is thick.

Mark the center of the planned circle, and drill a hole that the threaded rod post will fit in snugly. Set the post at the desired distance from the router bit, and tighten the handle on top to lock it in place. If you are cutting all the way through your material, make sure to hang the portion being cut off the table, and keep rotating the material periodically during the cut to keep from cutting the table.

You could also put a sacrificial piece of scrap underneath the material instead. It's generally safer and easier to cut outer edges of circles in a counter-clockwise direction, and inside edges clockwise.

If you don't want a small hole in the cener of whatever you're cutting, you can use a sacrificial piece on top. You might want to watch by build videos of this project to see a step by step tutorial on how to build this jig.

They are on this page below and also on my YouTube channel. I have also listed the tools and materials I used in this project below.

If you would like to build this jig yourself the follow the link below to download my CAD and Sketchup template. If you want me to build one for you or if you would like to buy the hardware kit pivot pin assembly then follow that same link to my RedneckDIY store. Good luck! Follow this link to download the template. Array Array Array Array. Redneck DIY. I made sure to go back after drilling my holes and countersink the holes so that the jig will sit flush to the work piece.

The center hole can be drilled out or you can simply plunge your router through carefully! I opted to drill the hole out because I wanted it to be a bit bigger than my router bit. Make sure to follow me as next time I'll be teaching you how to use this circle jig to make a hula hoop!

If you like these types of jigs and woodworking in general, make sure to join me on my YouTube channel, Click Clack Clunk! By clickclackclunk My YouTube Channel! More by the author:. About: I love woodworking and tinkering and make new videos about it every week! Come join me on my YouTube channel! More About clickclackclunk ». Wheels for wooden kids toys 2. Table tops 4. Let's have some fun!

Tools: A plunge router - I use a Makita Plunge router and you'll need this for the jig and for making the jig A 4mm router bit and a 8mm router bit A drill for making the necessary holes A drill bit the size of your selected screws see below and a countersink Straight edge Carpenter's Pencil these are great, you'll never lose them!! A good set of Bar Porter Cable Router Circle Cutting Jig Clamps Materials: Two machine screws to affix your jig to your router it may be more according to your router's base A washer and a long bolt with a nut.

I used an m6 bolt which was 3cm long. A piece of wood that is no thicker than 1cm. The width and length of the wood is up to you and can be defined by your exact needs. Mine was 8cm wide and about 70cm long. An extra scrap of wood for the knob, or a plastic knob with a hole for the m6 screw.

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