Circle-cutting jig

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Project by Routerisstillmyname posted 11-10-2008 04:15 AM 5366 views 8 times favorited 8 comments Add to Favorites Watch

Pic1 is my old circle-cutting jig I had made back in 92. It’s extremely accurate and has served me well all these years but setting it up was time consuming at times. It usually took 2-3 tries to get it exact with odd circumference circles.
Pic2, 3 are my new CCJ and it is designed for quick and precise setups. It’s based on zero reference calibration and as usual it’s for my DW625 and it’s smaller brother DW621.
The zero reference calibration makes it a breeze to set the circumference no matter what size router bit I use since the center of router bit is 100% adjacent to the center of pin which is calibrated to zero ruler scale with 1/32nd increments.
It’s open-end design hence capable of cutting circles from 1-17 inches or by reversing the rod (pin distance) it can cut 30-inch circles currently. If I need to cut even much larger circles, I swap out the rod with a longer one. Due to open-end design the back of the Lexan can be vulnerable if you are accident prone like me so I added reinforcement to the back.
It has a large rounded off opening for dust extraction and rounded sides to allow smooth glide.

-- Router è ancora il mio nome.

8 comments so far

View lew's profile


13534 posts in 5215 days

#1 posted 11-10-2008 04:49 AM

Nice Jig!

I like the idea of using clear Lexan. It is so much easier when you can see the layout lines. I don’t know why all router bases aren’t made from this material.

-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View Rustic's profile


3260 posts in 5056 days

#2 posted 11-10-2008 04:59 AM

I like it as well. Quite ingenius.

--, Rick Kruse, Grand Rapids, MI

View woodworm's profile


14477 posts in 5050 days

#3 posted 11-10-2008 07:07 AM

Great circle cutting jig.
The idea of using acrylic clear plastic sheet is great!
Is it easy to get?

-- masrol, kuala lumpur, MY.

View SawDustnSplinters's profile


321 posts in 5241 days

#4 posted 11-10-2008 05:44 PM

I really like the clear material, I was just thinking the other day when I was trying to rout out a cedar wood sign per KingsTreasures helpful instructions and how it would be so much easier to see the lines if I just took the darn black base off.

Anyway, nice work…

-- Frank, Dallas,TX , , “I have a REALLY BIG chainsaw”

View ratchet's profile


1391 posts in 5247 days

#5 posted 11-10-2008 05:44 PM

A superior jig! Nice work. Want to sell me one?

View TNwoodchuck's profile


102 posts in 5235 days

#6 posted 11-11-2008 02:43 AM

Elegantly simple! Ratchet beat me to the punch. I was thinking you could sell me that “prototype” for your new model that would work on my DW621, then you could make yourself a “new and improved” version.

Thanks for taking the time to share the excellent fruits of your thinking and labor.

-- Chuck near Nashville - “All you are unable to give possesses you” (Andre Gide)

View Routerisstillmyname's profile


763 posts in 4969 days

#7 posted 11-12-2008 02:04 AM

Thank you all for comments.
As far as making and selling them, even if I had more time on my hand to make a few, I wouldn’t be able to make and sell and ship at a reasonable price.
(But they are not complicated to make and if anyone needs a few tips just email/PM me, I’ll be glad to help)
The prices on poly carbonate and Lexan and aluminum have gotten outrageous this past couple of years not to mention the highway robbery when it comes to shipping these days.
Used to be able to go to a scrap pile and grab few reasonable size sheets of Lexan and walk out with just spending 10-15 dollars. Not any more. The little piece of aluminum cost me 8 dollars for shipping.
Sometime you can find good deals of Lexan on eBay but we all know what shipping is like on eBay.
Of course, you can make the same thing using wood but you do lose the benefit of clear view cutting.

-- Router è ancora il mio nome.

View woodworm's profile


14477 posts in 5050 days

#8 posted 11-12-2008 03:00 PM

Yes you’re right. A circle cutting jig with capacity of cutting 7” to 19”maximum may cost us $52 each (excluding shipping cost).
Beside saving some $ by making our own jig instead, there is something we get that can’t be measured by $ sign, ie self satisfaction. Most of us here have that pride (except and of course to certain degree, those making furniture as a profession).

-- masrol, kuala lumpur, MY.

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