Phydeaux
Superficially Profound
Registered: 02/12/06
Posts: 2012
Loc: New Hampshire
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I've been trying to figure out a good way to make a router jig for cutting small circles, smaller than the router base. One application I've seen for that is speaker holes.
I like the idea I've seen of using a standard bushing in the router's base plate to center the router on the jig so the router can rotate in the jig, letting your hands stay in position on the router.
What I'm trying to figure out is an elegant way of adjusting for different circle sizes, without going crazy elaborate.
Anybody got one like this they've made?
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Phydeaux
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wingnut
Member
Registered: 01/19/05
Posts: 102
Loc: Altoona, IA
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I have a Jasper jig, and it is excellent. Very easy to use and also very accurate... but I did not make it sorry.
Edited by wingnut (07/20/09 04:46 PM)
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meackerman
Moving Up Joe's List
Registered: 02/06/02
Posts: 15634
Loc: Northern CA
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the small Jasper Jig work well.
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www.meackerman.com
Reality is that which, when you stop believing in it, doesn't go away. - Philip K. Dick
Mark
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JGrout
member
Registered: 08/04/02
Posts: 16710
Loc: Grand Junction CO
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pretty simple and very adjustable
If I had to do one thing different it would be a smaller pin for the pivot I may go ahead and do that anyway.
Just for the sake of clarity this is a
router magic jig 
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FJS
"a man with experience is never at the mercy of one with only an opinion. "
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Phydeaux
Superficially Profound
Registered: 02/12/06
Posts: 2012
Loc: New Hampshire
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JGrout, that looks like it may be the ticket. I've got a few questions.
How small a circle will it cut? Looks like pretty small.
It looks like it's intended to attach to the router in place of the standard base plate. Do you believe it would work OK to make the hole the same size as a standard bushing and just let the router ride on it with the bushing to keep it aligned?
The slider is T-shaped, which looks like it would require a T-bit to cut the slot. I started to ask if that shape was necessary but then realized that the T is part of the clamping mechanism to hold the radius setting. Right and right?
Is that pin something exotic like a hunk of a finish nail?
Thanks! This appears to be just the sort of elegance I was looking for.
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Phydeaux
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JGrout
member
Registered: 08/04/02
Posts: 16710
Loc: Grand Junction CO
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Phydeaux said:
JGrout, that looks like it may be the ticket. I've got a few questions.
How small a circle will it cut? Looks like pretty small well I have not tried it but for a circle that would be the same as a plug you could get 3/8" pretty easy, 1/4" is possible with the right bit. I think even 1/8" could be done but the bit would tend to be rather wobbly. If your intent is to cut plugs do not cut all the way through the mother board, leave a little attached and remove after you have cut the plug. otherwise it will just chew it up.
It looks like it's intended to attach to the router in place of the standard base plate. Do you believe it would work OK to make the hole the same size as a standard bushing and just let the router ride on it with the bushing to keep it aligned? as long as it was tight on the bushing I don't see why not. I think I would still attach it with one more screw or a pin in a registration hole in the base just so it did not rotate while you were cutting.
The slider is T-shaped, which looks like it would require a T-bit to cut the slot. I started to ask if that shape was necessary but then realized that the T is part of the clamping mechanism to hold the radius setting. Right and right? Right and right . A dovetail bit would accomplish the same thing, I just had the bit. A rabbet cut then a keyhole bit made the step cut to finish it.
Is that pin something exotic like a hunk of a finish nail? yes just a finish nail. I would suggest a light brad (what I intend to do.) You also understand the arm is reversible for bigger circles as well
Thanks! This appears to be just the sort of elegance I was looking for.
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FJS
"a man with experience is never at the mercy of one with only an opinion. "
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JWA
Member
Registered: 12/08/04
Posts: 479
Loc: Columbus, Ohio
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meackerman said:
the small Jasper Jig work well.
+1 or +2 for me, too! I've used the Jasper for holes as small as 3" OD up to 15" JBL speaker cutouts. Even Fender Twin Reverb speaker baffle holes that are not 100% round are fairly easy to produce with this jig.
I'm using a PC690 but there are numerous base plate configurations that I'm sure work with many or all of the popular fixed bases.
For the money it was simple to use, durable and so far quite reliable. It does not provide any user caused problems which should have been designed out I'm thinking................
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Billy B
Member
Registered: 02/02/07
Posts: 216
Loc: Frankston, Texas
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JGrout's post has a good suggestion. The instructions of how to make are in Bill Hylton's book "Router Magic"  . It's easy to make and will cut perfect holes, including very small ones. You can't go wrong with this jig and it costs practically nothing to make. By changing the length of the sliding pin rod, you can also make quite large dia. discs.
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Billy B.
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Pirate
Member
Registered: 08/12/06
Posts: 1325
Loc: SW FL
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I made one like JGrouts. I also routed a recess for PC bushings, so I don't have to remove the base if I need to do some bushing required job.
The idea of having a bushing ride in the jig is something I am planning on trying. It would keep you from having to change hands while turning the jig.
When I get out to the shop, I might see if I could mount a bushing facing up, with a bushing on the router, that would index in the first bushing.
I also made a jig with different size holes in it, for making holes. Using different bushings and bits, you can cut many different size holes. In some book or mag. I saw the plan with a chart of different holes/bushings/bits to use for the different size holes.
Warning. Be sure to carpet tape the inside of the circle down as well as the outside. You don't want the disc trying to find a way out, once it is free! [image] [/image]
I enjoy making shop jigs as much as the projects they create.
I find it more enjoyable to make a jig when I have spare time, and am not in a hurry to make and use it. Those jigs usually aren't pretty!
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I long for the days when Coke was a soft drink, and Black and Decker was a quality tool.
Happiness is a snipe free planer
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Pirate
Member
Registered: 08/12/06
Posts: 1325
Loc: SW FL
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Besides using the circle jig I posted, I use a jig on the router table with a pin in it to cut discs. For discs I use the table.
Rough cut on the band saw then trim on the router table.
One advantage of having a TS extension router table is that you can trim the edge of very large round table tops. Can also be done with a large circle jig on a hand held router.
When possigle I like to rout on the table.
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I long for the days when Coke was a soft drink, and Black and Decker was a quality tool.
Happiness is a snipe free planer
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