Circle Cutting Jigs
Version 3



   Just after I built Version 2, I tried to cut some small circles about 10" in diameter.  I realized that I couldn't, because the eyebolt extends below the jig and therefore can only get as close to the blade as the edge of the band saw table.  On my saw, that's about 7" away from the blade.  Realizing that I was limited to making circles larger than 14" in diameter, I knew it was time to build yet another version. [sigh]

  

   This new version consists of three strips of plywood (approx 3" x 40") running parallel along a piece of ¼" hardboard.  The outer two strips are glued and screwed to the hardboard.  The strip in the center slides in and out between the other two.

   Near the end of the sliding strip is a small screw protruding up approx 3/8" through the wood.  The screw is countersunk from the bottom so that the wood can slide smoothly.  A single hex nut, which is also countersunk so that it sits flush with the top of the wood, holds the screw in place.

   The screw is about 1.5" from the end of the strip of wood, so I should be able to cut circles as small as 3" in diameter now.

   Another benefit of this "sliding jig" is that I can now slide the jig in toward the blade while the blade is cutting.  I no longer need to trim one end of the workpiece to the exact desired radius so that it will fit against the blade.  I can now turn the workpiece into the blade and simultaneously slide the jig toward the blade.  This causes the blade to cut a spiral in toward the desired radius.  Once the desired radius is reached, I clamp the back end of the sliding piece to the end of the hardboard with a couple of spring clamps to secure it in place.

  

   I also added a brace along the bottom near the back end of the jig that has a dado sized to accept the standing brace that I built for Version 2.  The jig has proven to be very stable during numerous cuts.

   I recently cut two circles (9" and 11" in diameter) for another project and this new version of the jig worked great.  Hopefully, this will be the last one I have to build for a while.


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