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15 years ago
How about making a template and using a bearing guide? I've done it a lot..works great
The template idea had occurred to me but I would still be left with the problem of how to make a perfect template.
Huh. It figures that you could buy a jig for this!
Thanks all for your help. This group is the greatest! I went with the tablesaw jig. You have to make a LOT of passes to get a very round circle but it does work. If I were to do this again, I would probably go with one of the router ideas but for 4 wheels, it isn't that big a deal. I have saved all of your ideas for the future in case I go heavy into the circle making business!!
Thinking of going into the Merry-Go-Round business?
you can also make a crosscut sled for a table saw (a useful item anyway). Then, drill a hole through the center of your stock, and screw it into the sled 5.5 inshed from the blade. Take the corners off first, and then crefully rotate the stock. I've seen it done in a video, but I forget where. You can either make the rest of the wheels that way, or you can use the wheel as a template for a flush trim router bit (use double-stick tape) You can also make a blank out of masonite shelly
You have a year or two on me, but my standard disclaimer is now, its not my fault if you didn't understand what I thought I meant to say.
Mike M
REAL MEN Do it on a router table.
Cut four square blanks 5-5/8 on TS Drill pivot holes in centers of each Scribe Circle 5-5/8 circumference on each face Cut / remove waste Jigsaw / Sander Mount Pivot Pin in Miter Bar Mount Mitre Bar w/pin in Router table (You must be able to "lock" the bar in place) Mount best router bit Mount first blank and, with mitre bar loose, rotate piece to find a good starting place for cut Repeat with each blank until you find place the works for largest dimension on any blank. Fix pivot point/mitre bar at that location Cut all four blanks Adjust pivot point Cut all four blanks Adjust pivot point Cut all four blanks Replace router bit with small sanding drum Adjust pivot point Sand all four blanks
If you want bottoms of wheels rounded, switch from straight bit to cove bit after initial sizing and mount each finished "wheel" in drill press and finish sand them there.
Affix a piece of scrap wood to the router table
Real men probably don't feel the need to brag about where they do it.
"Hoosierpopi" bragged
You must have one of those aircraft carrier router tables.
REAL men use their teeth and intimidate the wood into being round..
mac
Please remove splinters before emailing
...I'm with you, man...buy the hole saw, get perfect circles, save mucho time.
cg
Price out a 5-1/2" hole saw and then a fly cutter.
Might make a different suggestion.
Lew
Or a Woodpecker. We were living in the house we were finishing, and we hadn't sided the gable ends, one of which was the extension of our bedroom wall. I was awakened to the sound of a mini jackhammer on the outside of the house. By the time I threw on some clothes and wandered outside, the little guy was finishing up his own access hole into the attic.
I climbed over the scaffolding and saw a perfect circle cut into the sheathing. And I mean perfect, I got a tape and measured it... remarkably accurate.
So, I tacked up some sheet metal over the hole to keep him out. Next morning, about 6am.... BAM!-BAM!-BAM!-BAM!-BAM!-BAM!-BAM!
OK, I tried it out. Make a crosscut sled for your table saw, if you don't already have one. Cut your stock to size, and drill axle holes in the center. Make sure you have some bolts the same exact diameter as the holes.
Take a piece of 3/8 plywood, and countersink a bolt through it, so that you can bold the wheel to the plywood, and wtill have it turn freely. (I did this to avoid drilling holes in the sled.)
Cut the plywood so that the countersunk bolt is exactly 5.5 inches from the blade. use a clamp to hold the position of the plywood, for the next wheel.
First, used the sled to take off the corners of the wheel. As it rounds out, start spinning the wheel. Hold the wheel securely, and don't try to take off too mych at once (move the sled so that a little of the wheel is done at one time.
I did it for a round clock, it worked like a charm. Of course, ruined the piece trying to use a roundover bit on the front. I may try to use the table saw for that as well!
good luck
shelly
Now, if you can only get him in your tool drawer . . .
" I need to cut four 5 1/2" wheels out of 3/4" oak"
"Cut the plywood so that the countersunk bolt is exactly 5.5 inches from the blade." > shelly
Shelly, Shell, Shelly,
2.75" from the blade! And, watch your fingers!
I wouldn't want a woodpecker in my drawers. I'm just sayin'...
Too........many........jokes.........can't.........compute...........
point take (I'm an idiot sometimes)
I stood on the side of the saw, kept one hand on the bolt, and turned from the other side. I've learned respect for a TS the hard way.
shelly
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