Hello, dear readers and homemade products !
When making homemade products from wood and materials such as plywood, chipboard, MDF and others, the task of cutting circles out of them often arises.
In this article, the author of the YouTube channel “Inspire Woodcraft” will tell you how you can make a device for cutting circles of different diameters on a band saw.
You have probably already met all kinds of such devices. The most common is a circular nozzle for a hand router, about which there have already been several articles on this site.
However, the equipment offered by the author compares favorably with others in that it is fully adjustable, practically does not chip, and especially drilling holes in the center of future discs.
< br> – Double-sided tape, oil-wax
– Titebond II wood glue, two-component second glue, epoxy resin, sandpaper.
Tools used by the author.
– Band saw, band saw blades
– Manual router
– Insert plate with rings for milling table
– Wood cutters
– Screwdriver, countersink, Forstner drills
– Circular saw
– 3D safety pusher
– Adjustable angle stop for T-track < br> – Orbital sander
– F-clamps, spring clips
– Universal gage planer, tape measure, marker.
So, the band saw table is often equipped with a so-called T-slot, which serves to install various devices. It will also serve as a guide for the future carriage.
For such grooves, you can use a ready-made slider, or make its simplest analogue yourself.
This is what the master will do. First, the dimensions are measured – the width and height of the T-track.
The runner itself is cut from a wooden beam ( it must be hardwood) on a circular saw.
milling table. This is a homemade milling table with a plate with replaceable rings installed on it.
The finished specimen of the runner sits in the T-track not too tightly, and at the same time does not dangle, all its sides are smoothly cleaned.
Next, a rectangular blank for the base is cut from the plywood sheet on a circular saw. The thickness of the plywood must be 20 mm or more – this is needed to form a groove in it.
A finished runner is glued to the lower part of the base at a distance of 22 cm from the edge (slightly more than the distance from the canvas to the T-track). Two types of glue are used here: super glue on the edges and in the center, wood glue on the rest of the runner surfaces. Superglue acts as a quick fixer, while wood glue provides a durable bond.
The base plate is slid into the T-track and the first cut is made. It runs parallel to the T-track.
The incision is made until the edge of the base closest to the author is aligned with the edge of the table.
The position is then marked on the edge of the base where the bounding box will be placed.
The latter is made from scraps of maple planks from which the runner was made.
The bounding block is glued so that it protrudes below the base and rests against the edge of the table.
Then the author marks a line along which the dovetail groove will run. The latter will be located perpendicular to the plane of the band saw blade.
It is important that the center of the groove is perfectly flush with the blade's cutting edge (s). Otherwise, there will be problems with the centering of the blade, and it may be skewed.
The groove is milled with a hand router along the guide. It uses a dovetail cutter.
This form of the groove was chosen by the author as the simplest, because there will be no special loads on it. Otherwise, you would have to bother cutting out the T-slot.
< img class = "aligncenter" alt = "How to make a carriage for cutting circles on a band saw without a hole in the center" src = "https://usamodelkina.ru/uploads/posts/2021-01/1610657953_len-082.jpg"/> The edges of the finished groove are cleaned with sandpaper wrapped around the bar. < br> Now a disc is made from a cut of a wooden dowel, from which the head of the pressure screw will be made. It will also be a kind of center of rotation of the processed parts.
In the center of the round timber, a through hole is drilled for the screw. Using a countersink, a recess is formed under the screw head.
A screw is inserted into the hole. A nut is inserted into the groove in the carriage, and a screw is screwed into it. It looks like a pressure mechanism.
Next, the components of the fast-setting epoxy glue are mixed, the hole in the handle is coated with it, and the screw is glued in.
The next step on the plywood trim is the center, and a through hole is made in it with a Forstner drill with a diameter of 40 mm. This is exactly the diameter that our handle has.
The carriage is put in place, the workpiece is put on the handle and the ring is cut out of it.
Surplus wood from the remaining part is cut tangent to the carved circle.
The adjustable handle is set as close as possible, one might say close to the part with a semicircle cut out on it.
This design serves several different purposes at once. Firstly, it will serve as a support for the workpiece being processed, and minimizes possible chips on its underside. Secondly, this construction serves as a delimiter.
Further, the author places two rulers on the carriage parallel to the cut out groove so that between them there is a ring, put on the head of the central screw.
The block is glued to the carriage on double-sided tape so that if necessary could be quickly and easily replaced. For example, when worn out.
The author once again checks the distance between the rulers and marks the lines along which the overlays should be glued.
On both sides of the lined lines, plywood sheets of the same thickness as the ring are glued. Together they form a groove for the movement of the ring. It uses the same mixture of superglue and wood glue.
its place, and the master makes the final cut through the top layer of plywood.
Then the author cuts out some square pieces.
Marks are placed on the support ring to make it easier to align them with the lines marked on the square plywood pieces themselves.
The foreman now intends to carry out several test cuts. Its purpose is not only to check the effectiveness of the new equipment, but also to take a few additional measurements in order to later apply a scale on the carriage.
The same double-sided tape is used to fix the ring on the back of a square sheet of plywood.
< a href = "https://usamodelkina.ru/uploads/posts/2021-01/1610658043_len-231.jpg" rel = "prettyPhoto"> So, the workpiece is pushed with a ring onto the screw head with the carriage extended. Then the band saw blade is started, and the disc is cut out of the workpiece with a rotational motion. The beauty of this device is that you do not need any pins and holes in the workpiece itself or on the work surface. The glued ring serves as a temporary center.
Further, parallel to the groove in the carriage, marks are made at intervals of half an inch and a scale is obtained by which you can navigate when choosing the size of the diameter of the circle.
The author cuts out a few more discs and rings to check its accuracy.
If you wish, you can make the scale more detailed and put marks between each a couple of previous divisions.
All surfaces of the carriage are carefully processed with an orbital sander so that the processed workpieces do not get stuck anywhere. Burrs on edges and edges are removed with a sanding block.
Additionally, all planes, especially the groove itself and the groove, are rubbed with wax paste, which should reduce the friction of the workpiece on the carriage and the carriage on the table.
When fixing the ring to the workpiece, it is better not to leave excess tape so that they do not stick to the carriage and block the rotation of the part.
As a result, it is very easy to adjust the required radius of the future blade. < br> The only difficulty that you may have when using this equipment is some shakiness of the carriage, the base platform. However, this becomes perceptible only when cutting out circles of large diameter, starting from 60 cm.
In this case, the author recommends substituting some kind of support under the hanging side of the platform. The second way is to make the carriage wider to overlap the second T-track in the table and install another runner on the carriage.
Thank the author for a simple but useful tool for cutting discs and circles on a band saw.
Good mood, everyone, good health, and interesting ideas!
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The author's video can be found here.
Hello, dear readers and homemade products !