Replies

1. 
   AlanWS | Dec 12, 2006 04:13am | #1

   For diameters up to 3", you can glue up stock and mill a long piece with a square cross section the size you want. Now take off the corners with a roundover bit to make a dowel with the grain running crosswise, and then cut slices to make the wheels. The only trick is to leave a little of each end square as you cut the roundovers on the router table.

2. 
   joinerswork | Dec 12, 2006 08:58am | #2

   Rob,

   Holesaw?

   Ray

3. 
   oldusty | Dec 12, 2006 09:57am | #3

   Rob ,

               How about a circle cutter or fly cutter on the drill press ?

                                    dusty

4. 
   MikeHennessy | Dec 12, 2006 02:57pm | #4

   Besides the other suggestions, you can still use your router. Make a circular template, fix it to the workpiece with a screw if it doesn't matter that there is a hole in the center, DS tape if it does, and use a guide collar and a 1/4" bit to cut out the piece.

   Mike Hennessy
   Pittsburgh, PA

1. 
   robk | Dec 12, 2006 07:34pm | #5

   Wow, that was fast.  Thanks for the great tips; I knew there were some obvious workarounds, like a holesaw (!), that I hadn't considered.  The roundover bit idea is a great one, too.  I had tried the LeeValley's fly cutter, but it dulls so fast and is such a pain to sharpen that I started looking for other ideas.

   Thanks all!

1. 
   JohnWW | Dec 12, 2006 07:49pm | #6

   A fly cutter would be my first choice for doing this.  Run at low speed with a gentle feed it will produce a very clean cut.  Cut half way through the stock and then flip the board over and finish the cut from the other side of the stock. 

   I don't find fly cutter bits hard to sharpen, just takes a minute or two to sharpen them freehand on a grinder.  The angles aren't critical just make sure you have relief behind the cutting edge so that the sides of the bit aren't dragging in the cut.  The replacement cutters from Lee Valley are overpriced, they are just ordinary metal lathe bits that can be bought for a dollar or two each from a machinist's supply.

   A hole saw will produce a very rough disk that will need a lot of cleaning up.

   John White, Shop Manager, Fine Woodworking Magazine 

1. 
   robk | Dec 12, 2006 07:53pm | #7

   Thanks John!  Loved your shop machines book!

1. 
   JohnWW | Dec 12, 2006 10:42pm | #8

   Thank you.

   John W.

5. 
   Jim McDonald | Dec 13, 2006 12:49am | #9

   I cut all my wheels out using a circle jig on the band saw. Finish them up to final size using a similar jig on the sander.

6. 
   douglas2cats | Dec 13, 2006 02:02am | #10

   A disk sander would be my first choice, but there are a couple other ways a drill press could be used too after roughing the disk with a courser method (jig saw or whatever). If you don't mind a through hole, you can run a bolt through the hole and tighten the bolt into the chuck. Then any number of methods of putting a fence or block with sandpaper attached up to the spinning disk to round the disk. If you do mind the through hole, you can rotate the disk on a pointed pin with the edge just touching a DP mounted drum sander. Just a couple more options.

    

   If you build it he will come.