My band saw circle jig with video

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Project by Paul Pomerleau posted 03-07-2011 05:20 AM 7456 views 20 times favorited 13 comments Add to Favorites Watch

I’m in the middle of building my Thien Separator for my workshop, but I needed to make a circle jig first.
It is made of 1/2” plywood and 1/4” hardboard.
It has an adjustable stop block to ensure the teeth of the blade will stop at the top-dead-center of the arc before spinning the stock.
The pivot slider is adjustable with a locking thumb screw underneath.
I have three different types of sliders – a 1/4” dowel, a tiny pin and a 3/4” hole that will take a self adhesive dowel that will leave no marks on the stock when completed.
I tried to post a video that I made of cutting the baffle but couldn’t figure out how to post it in the video section here on LJ.
So I posted it to YouTube if you are interested in watching it.
Hope you enjoy it.

-- Close to Ottawa Ontario Canada

13 comments so far

View Dusty56's profile


11854 posts in 4249 days

#1 posted 03-07-2011 06:34 AM

Excellent jig and video …thanks for taking the time to share both with us , Paul : )

-- I'm absolutely positive that I couldn't be more uncertain!

View Woodenwizard's profile


1360 posts in 3604 days

#2 posted 03-07-2011 07:26 AM

I just realized that I need one of those! Thanks for the post. I may need to pick your brain as I work on my version of this jig.

-- John, Colorado's (Wooden Wizard)

View DaleM's profile


958 posts in 3945 days

#3 posted 03-07-2011 07:32 AM

Thanks for making the video. I have a very crude circle jig. I think I’ll make a new one with the adjustable stop on it, because after I watched your video, it just made sense. I also liked the removable sliders, especially the one you use with the double-sided tape; great idea.

-- Dale Manning, Carthage, NY

View steliart's profile


2895 posts in 3249 days

#4 posted 03-07-2011 07:53 AM

An excellent instructable on that jig. Thanks and very well done

-- Stelios L.A. Stavrinides: - I am not so rich to buy cheap tools, but... necessity is the mother of inventions !!!

View tyka's profile


142 posts in 3254 days

#5 posted 03-07-2011 03:17 PM

Excellent jig. The best I’ve seen so far. It’s amazing how it stays on the bandsaw table on its own. Excellent video! It should be on this site and I hope you find the way to do it. Lots of LJ’s would like it. BTW are you a teacher? If not, you missed your calling LOL Tks for sharing Paul.

-- Paul, Plantagenet, Ontario

View Don Johnson's profile

Don Johnson

715 posts in 3342 days

#6 posted 03-07-2011 03:23 PM

Very clear explanations of each step in your video, and a very efficient and easy to use circle cutter.

Having looked at a number of these, I think this is the one I shall mark for future construction.

One small point about the dowel centre – could the square part be made from something thinner so that that the stock sits flatter on the jig ? I appreciate that it has to be strong enough to stand repeated use of double sided tape, but an aluminium or brass square could be thinner than the wooden version – with perhaps a screw as well as glue to hold it to the dowel whilst the sticky stuff is being removed ?

-- Don, Somerset UK,

View harrywho's profile


123 posts in 3793 days

#7 posted 03-07-2011 04:27 PM

Neat! Excellent tutorial and video. Thanks.


-- Harry, Indiana

View Ken90712's profile


17794 posts in 3750 days

#8 posted 03-07-2011 06:25 PM

Great jig and video! Well done and very informative. I have to use this idea, thx for sharing!

-- Ken, "Everyday above ground is a good day!"

View Mike Gager's profile

Mike Gager

665 posts in 3828 days

#9 posted 03-07-2011 07:14 PM

nice job! good video

View Bricofleur's profile


1466 posts in 3754 days

#10 posted 03-11-2011 12:49 AM

Nice jig Paul. I particularly like the sliding guide made from beveled 1/4’’ hardboard in combination with the top. Clever! No guessing and cheap.



-- Learn from yesterday, work today and enjoy success tomorrow. --

View Hacksaw's profile


185 posts in 3937 days

#11 posted 03-12-2011 06:05 PM

Love the Jig.Love the video.One small thing though…why self adhesive center pins? Why not just put a pin all the way through? That simplifies the process (just having to flip it over not try to perfectly line up the marks),insures that the cut is not angled because the piece is directly resting on the jig and is easily filled with a dowel(if needed)

-- Nothing's just gets expensive

View Grandpa's profile


3263 posts in 3236 days

#12 posted 03-12-2011 06:44 PM

Excellent video and lesson. I made a jig like this one many years ago but you refined yours much more. Mine was a one time use jig but you are correct in thinking this is a must have if you cut circles of wood. I also appreciated your math lesson. I try to tell young people that they will use math for the remainder of their lives and they should pay attention in class. Thanks for the re-enforcement. Now we have to carry this lesson to them and show them why and teach them some safe woodworking. BTW I was educated years ago as an Industrial Arts teacher but I actully supported my family by using my drafting. You did a great job. Thanks

View Chefshep's profile


121 posts in 3244 days

#13 posted 03-18-2011 05:38 AM


Awesome job on both the jig & tutorial! In my Favs… This one is a must have for sure!

Thanks for sharing this one. I have been thinking about the Thien Separator for a few weeks now. So I have no good excuse for putting it off anymore.

Good post!

-- Chefshep :) "When we allow our present to quarrel with our past, we risk jeopardizing our future.” - Winston Churchill

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