I am making a clock patterned on a New Hampshire “coffin clock” by a maker named Tabor. The front door is 9 1/2″ X 29″. I need to cut a 7 1/2″ circle in the door for the dial/glass. Is there an easy way to cut this opening as cleanly and perfectly as possible?
A 7 1/2″ hole saw would be perfect, but no one seems to make them (and it would probably cost an arm and a leg). Is the answer simply using a compass and jigsaw?
Thanks – Jason
Replies
With a router.
If you have a router, that's an easy tool with which to cut large circles. There are all manner of circle-cutting jigs you can make or buy, but for a one-off use, just make a trammel out of a piece of thin plywood. Use a nail for the center point and attach it to the router with double-sided tape or your method of choice at the right distance to cut the radius of your choice. Use a straight bit in the router, and make several progressively deeper cuts through your stock.
It's best to fasten your stock to a scrap backer board so the cutout circle stays in place after the cut is completed.
1" pivot points on this plate, drill pivot to suit. This plate cuts circles on 2" centers.
Routers.
Edited 1/7/2007 6:58 pm ET by Routerman
Thanks for advice. I hadn't even thought of using the router.
Jason
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