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Bandsaw Circle Cutting

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Bandsaw Circle Cutting CIRCLE-CUTTING JIG © 2012 August Home Publishing Co. best-built jigs & fixtures band saw Circle-Cutting Jig In just an afternoon, you can build a simple accessory that makes creating perfect circles a snap. The band saw is without a doubt one of the most you rotate it through the cut. An adjustable pivot versatile tools in the shop, especially when it comes pin that’s mounted in this base, as well as a heavy- to cutting curved or round parts. And with the jig duty aluminum bar, work together to allow you to you see above, you can even cut perfectly shaped cut circles up to 38" in diameter. circles quickly and reliably. Finally, a unique stop system lets you align the The jig’s base is made from phenolic plywood. pivot pin with the front edge of the blade. This way, This type of plywood has a durable, slick surface the jig automatically stops at the correct point for you that makes it perfect for supporting a workpiece as to begin rotating the workpiece for the cut. 1 WoodsmithPlans.com SN11324 ©2012 August Home Publishing Co. All Rights Reserved. A B C D E F G H I J K L M N O P Q R S T U V W X Y Z AA BB C C DD E E F F GG HH I I J J KK L L MM NN OO P P QQ RR SS T T UU V V WW X X Y Y Z Z AAA BBB CC C DDD EEE F F F GGG HHH I I I J J J K KK L L L MMM NNN OOO P P P QQQ RRR SSS T T T UUU V V V WWW X X X Y Y Y Z Z Z CL EXPLODED VIEW OVERALL DIMENSIONS: (24!/2" x 24!/2" x 24!/2") PART NAME CALLOUT Sizing the Base. To get started, 1 you’ll want to measure the width PHENOLIC PLYWOOD TOP VIEW PROVIDES A DURABLE, and depth of your band saw table. SLICK SURFACE END VIEW I sized the jig base 4" larger in both A B C D E F G H I J K L M directions to provide solid support SIDE VIEW A B C D E F G H I J K L M N O P Q R S T U V W X Y Z for the workpiece (Figure 1). BASE N O P Q R S T U V W X Y Z (18" x 18" - #/4" Ply.) AA BB C C TOPDD EVIEWE F F GG HH I I Locate the Runner. An alumi- (CROSS SECTION) AA BB C C DD E E F F GG HH I I J J KK L L MM NN OO P P QQ RR num runner rides in the miter slot J J KK L L MM NN OO P P QQ RR SS T T UU V V W W X X Y Y Z Z to align the jig for the initial cut STEP 1: XXXX SS T T UU V V WW X X Y Y Z Z AAA BBB XXXXXXXXXXXXXXXCC C DDD EEE F F F into the workpiece. (I’ll talk more SECOND: MARK AAA BBB CC C DDD EEE F F F LOCATION FOR GGG HHH I I I J J J K KK L L L about that later.) To locate the run- RUNNER GGG HHH I I I J J J K KK L L L MMM NNN OOO P P P QQQ RRR MMM NNN OOO P P P QQQ RRR ner, place the base on the saw X X X SSS T T T UUU V V V WWW SSS T T T UUU V V V WWW X X X table with the left side of the base FIRST: POSITION Y Y Y Z Z Z C BASE FLUSH WITH L Y Y Y Z Z Z C flush with the edge of the saw table. INSIDE EDGE L OF TABLE After marking the location of the “QUOTE MARKS” miter slot, cut a shallow dado sized EXPLODED VIEW OVERALL DIMENSIONS: EXPLODED VIEW to fit the runner (Figure 2). You can NOTE: EASE ALL EDGES !/2 !/2 !/2 OVERALL DIMENSIONS: WITH !/16" CHAMFER (24 " x 24 PATTERN" x 24 ") (24!/2" x 24!/2" x 24!/2") temporarily install the runner to complete the next step. PART NAME w/LETTER A B(firstC timeD E used)F G H I J K L M N O P Q R S T U V W X Y Z FIGURE CALLOUT AA BB C C DD E E F F GG HH I I 2 CALLOUT J J KK L L MM NN OO P P QQ RR TOP VIEW TOPSS TVIEWT UU V V WW X X Y Y Z Z DDD EEE F F F END VIEW AAA BBB CC C CUT DADO FOR ENDGGG VIEWHHH I I I J J J K KK L L L RUNNER AND " TEMPORARILY SIDE VIEW SIDEMMM VIEWNNN OOO P P P QQQ RRR ATTACH WITH SCREWS #8 x 1" Fh SSS T T T UUU V V V WWW X X X WOODSCREW TOP VIEW Y Y Y Z Z Z (CROSS SECTION) !/2 TOP VIEW C #8 x 1 " Fh (CROSS SECTION) L WOODSCREW #8 x 2" Fh 1!/4" 1!/2" 1#/4" a. STEP 1: XXXX XXXXXXXXXXXXXXXWOODSCREW STEPEXPLODED 1: XXXX VIEW XXXXXXXXXXXXXXXOVERALL DIMENSIONS: #/4 !/2 !/2 !/2 FIRST: XXXXXXX (24 " x 24 " x 24 ") XXXXXXXXXXX FIRST: XXXXXXX XXXXXXXXXXX PART NAME w/LETTER RUNNER (first time used) (#/4" x 18" - #/8" Alum.) !/16 #/4 #8 x " Fh “QUOTE MARKS” WOODSCREW “QUOTECALLOUT MARKS” PATTERN PATTERNTOP VIEW Making a Saw Kerf. The next 3 END VIEW task is to create a kerf in the base. FIRST: SLIP SIDE VIEW This kerf locates the end of the RUNNER INTO stopped groove that will be used to MITER SLOT TOP VIEW house the adjustment bar. (CROSS SECTION) Cutting this kerf is a simple mat- STEP 1: XXXX ter. Just turn on the saw, set the XXXXXXXXXXXXXXX runner in the miter slot, and push FIRST: XXXXXXX the base forward into the band saw XXXXXXXXXXX blade. Proceed slowly, so you don’t #8 x 1" Fh SECOND: CUT SAW WOODSCREW cut too far into the piece. Once the KERF UNTIL BACK EDGE #/4 #8 x 1!/2" Fh 3 EXTENDS " PAST BACK back edge of the base extends ⁄4" EDGE OF TABLE WOODSCREW !/2" #/4" #8 x 2" Fh 1!/4" 1 1 “QUOTE MARKS” !/2" #/4" past the back edge of the table, you WOODSCREW #8 x 2" Fh 1!/4" 1 1 can stop the cut, as shown in Figure WOODSCREW 3 at right. At this point, you can turn NOTE: THE DIAMETERPATTERN OF THE BIT your attention to making the adjust- AND THE DEPTH OF CUT DETERMINES THE SIZE OF YOUR WORKPIECE ment bar, which we’ll show you how to do on the next page. WASTE !/4" 2 WoodsmithPlans.com SN11324 ©2012 August Home Publishing Co. All Rights Reserved. !/4 FULL DIAMETER OF BIT USED END VIEW TO ROUT PROFILE FENCE #8 x 1" Fh WOODSCREW #8 x 1!/2" Fh WOODSCREW #8 x 2" Fh 1!/4" 1!/2" 1#/4" WOODSCREW CUT SAW KERF UNTIL BACK EDGE OF BASE THE DIAMETER OF THE BIT IS FLUSH WITH EDGE NOTE: NOTE: THE DIAMETER OF THE BIT OF TABLE AND THE DEPTH OF CUT DETERMINES THE SIZE OF YOUR WORKPIECE AND THE DEPTH OF CUT DETERMINES THE SIZE OF YOUR WORKPIECE WASTE WASTE !/4" !/4" !/4 FULL DIAMETER !/4 FULL OF BIT USED DIAMETER END VIEW TO ROUT OF BIT USED PROFILE END VIEW TO ROUT FENCE PROFILE FENCE NOTE: THE DIAMETER OF THE BIT AND THE DEPTH OF CUT DETERMINES THE SIZE OF YOUR WORKPIECE WASTE !/4" !/4 FULL DIAMETER OF BIT USED END VIEW TO ROUT PROFILE FENCE A B C D E F G H I J K L M N O P Q R S T U V W X Y Z A B C D E F G H I J K L M AA BB C C DD E E F F GG HH I I Q X Z N O P R S T U V W Y J J KK L L MM NN OO P P QQ RR AA BB C C DD E E F F GG HH I I SS T T UU V V WW X X Y Y Z Z J J KK L L MM NN OO P P QQ RR AAA BBB CC C DDD EEE F F F SS T T UU V V WW X X Y Y Z Z GGG HHH I I I J J J K KK L L L AAA BBB CC C DDD EEE F F F MMM NNN OOO P P P QQQ RRR GGG HHH I I I J J J K KK L L L SSS T T T UUU V V V WWW X X X MMM NNN OOO P P P QQQ RRR Y Y Y Z Z Z CL SSS T T T UUU V V V WWW X X X Y Y Y Z Z Z NOTE: SEE SHOP SHORT CUTS EXPLODED VIEW FOR CUTTING GROOVE FOR OVERALL DIMENSIONS: MAKE PIN FROM !/16" ADJUSTMENT BAR (24!/2" x 24!/2" x 24!/2") FIGURE DRILL BIT AND EPOXY (PAGE 5) EXPLODED VIEW attaching the 4 INTO HOLE OVERALL DIMENSIONS: (24!/2" x 24!/2" x 24!/2") END OF GROOVE PART NAME w/LETTER ALIGNED WITH (first time used) !/2 SAW KERF 1 PART NAME w/LETTER Bar & Stop (first time used) CALLOUT #/8"-WIDE PART NAME !/16"-DIA.
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