Replies

1. 
   TomMGTC | Jun 22, 2002 12:42am | #1

   I would rough out the discs with a bandsaw for the OD and a jigsaw or scroll saw for the ID and finish them up with a with a router using atemplate and a pattern bit. Leave about 1/16 of and inch from you're cut line when you rough them out and the flush trim bit will make quick work of it and all the parts will be identical.

2. 
   TomMGTC | Jun 22, 2002 02:45am | #2

   Use a router and circle jig to cut the pattern and you can have perfect concentric circles.

3. 
   MichaelLomax | Jun 22, 2002 08:12pm | #3

   Careful using the flush trim bit to cut circles.  As you transition from edge grain to end grain crazy things can happen.  No matter the feed direction the router bit will occasionally grab things go downhill fast from there.  A spiral cutting bit will help but it can still prove to be difficult to cleanly and safely rout circles.

   I have had better luck with the circle cutting tool mentioned in a previous post.

   Good luck and be safe.

   lomax

4. 
   r_ignacki | Jun 23, 2002 04:12pm | #4

   once made 1000 wine racks, out of various hardwoods, the job needed 3000 3" (or 3 1/2, can't remember)holes, in boards, to be ripped in half for the bottle cradle,anyhow, after going thru a couple of those adjustable circle cutters, we settled on a self feed bit, the kind the plumbers use, but took out the center screw and replaced it with a regular twist bit,  that was the fastest way to bore 3" holes with a drill press, I think we tightened up the belts a little so the thing would'nt slip.

   maybe you could combine that with another step to compleat the "ring" (perhaps the router method)

   maybe even a homemade lathe.... a standard drill, for maybe ten bucks you can get one of those tapered fittings with the dowel screw, put that in the chuck, and strap the drill to your workbench...... turn the 5" ring, then use the drill press, you would already have a centered hole....I would use redwood, my 2 cents.

   no turn left unstoned  

5. 
   phi | Jun 23, 2002 06:35pm | #5

   A thought on the circle cutters, suggested by jeff,

    because a circle cutter has a center drill bit and an arm with an adjustable cutter, Maybe you could mount two cutters on the "arm".

   That way you could cut your inside and outside diameter at the same time, and cut your work time in half. You still would need to clamp the work piece down somehow. Hope this helps you out and good luck with the circles, what are they for?

1. 
   UncleDunc | Jun 23, 2002 07:02pm | #6

   That makes sense. I would set the depth of the cutters so the inner circle cut through first, stop the drill press and remove the waste, then start up again to finish the OD. If both cuts finish at the same time, I would be afraid of things rattling around and getting scarred.

1. 
   phi | Jun 23, 2002 07:08pm | #7

   Good point about the circles getting caught between the two cutters, however you could use some double stick tape or screws to hold the work piece down. Those methods wouldn't obstruct the cutters.

6. 
   sschefer | Jun 23, 2002 08:10pm | #8

   Do you have a router table. You said a router was an option. If its in a table there is a method I know of to create the perfect circle and its really simple. First off, you need a way to boost production so if you were to cut several pieces to, say, 5 1/4" x 5 1/4" square and use 1/4" threaded rod through the center to hold them together you could then use a band saw to rough out the 5" circle. Once it was roughed out then take a 1 x 3 about 16" long and drill a hole in one end about 2" back and centered. Insert a  1/4" T (closet) bolt in the hole. Separate your rough cut pieces and place them one at a time onto the jig your just made. You can secure it with a washer and double nut so that it is free to spin but not sloppy. They only need to be hand tight.

   With a 3/8" or 1/2" straight cut bit in your router use a large spring clamp to hold the jig to the table. Make a mark on the piece that is exactly 2.5" from center, turn on the router and ease the piece into the bit, cutting up to the mark, then just spin the piece around and you'll have a perfect circle. Now take the pieces over to your drill press and  use a 3" Forstner bit to cut the inner circle. The hole that you drilled for the 1/4" rod will be dead center so it will be your guide. You could use a 3" hole saw but you'll be stopping after every piece to clear the waste. If you get moving along a a real fast clip, you'll need to cool the drill bit.

   To get the production level up, first makeup all of your blanks, drill them and put them together for sawing on the bandsaw. Once cut, take them all apart and do your cleanup routing and finally your inner circle drilling. If you mark your table where the edge of the jig is when your piece is the correct diameter then you wont have to mark each individual piece, just ease the jig up to the mark.

   Depending upon your router table, you may have to play with how you actually clamp the jig to the table. I have a 3" lip on my table and a big spring clamp works fine for me but it may not be the best solution for you.

   Steve - in Northern California

7. 
   r_ignacki | Jun 26, 2002 12:25am | #9

   a set screw holds the feed screw, easy.

   no turn left unstoned