GrahamT

How do you cut small circles?

When flush mounting drivers I know that I have to use a rabbet bit but how do I cut a perfect circle first? It cant be done with a jigsaw so I assume it is done with a router but how? If it helps this is my router

http://www.blackanddecker.com/produc...istByType.aspx

Thanks for the help

Allen Ross

Jasper prob makes the best circle jigs around, the Model 400 will do a 1-7 1/2 hole in 1/16th increments, with a 1/4 inch bit.

Snag the combo pack at PE with Model 200 and 400, you can that do 1-18 3/16" holes for only 50 bucks. part # 365-260

Or if you are cheap make one your self, mount a board to your router, with a center hole for your bit, measure from them out side of the cutting bit to the distance you want cut, drill a pivot hole and sink a nail in that into your wrk piece and you are golden.

Make sure you use something to secure the cut out to the baffle when cutting so when you are done the cut the cut out jig and router don't go flying all over the place. I usually tack down some scrap 2x4 to the rear of the baffle.

Member and Founder of the \"Its Never to Big or too Loud to have in a Dorm Club\"
Everyone in college should have a 9 cuft Tempest in their closest!

GrahamT

Good tips, I am cheap so how would I secure the board to the router base?

GrahamT

Nevermind I just figured it out, this helps me a lot.

Gerry S

Graham:

I used a DIY router jig as well and it worked very well.

-Gerry

Jason Dalton

What I find works quite nicely is setting up your bit so its just shy of going through the wood, that way the circle remains supported so you can make a clean cut, then you can just punch it through when you remove your router. Once you get use to it you can make an almost paper thin layer holding the circle up and its very easy to knock it out.

marc

small sciccors, HAHA