There are many ways to cut a circle in wood. You can use a jigsaw, a trim router a hole saw or even a table saw. The easiest way to cut a rough circle shape is to use the tool freehand. But if you want to cut a precise circle the best way is to use the tool in combination with a woodworking jig.
To cut an accurate circle with a jigsaw you can use a jigsaw circle jig. To cut a circle with a table saw you can use an adjustable table saw circle jig. These methods work but sometimes they can be quite tedious. One of the most important things when cutting with a jigsaw is to use the right jigsaw blade and quite often you end up with skewed edges. Using a table saw will ensure precise perpendicular edges but cutting a circle on a table saw is cumbersome and it is not exactly the safest method.
Using a trim router is the best way to cut a precise circle in wood. In combination with a router circle cutting jig, you will achieve the desired results. I have already built a router jig for cutting circles. It is a great jig, unfortunately, the only disadvantage is that after several turns with the router, the cable gets tangled. It’s not a big deal, but it’s not comfortable. This is not the case for cordless trim routers.
So I made an upgraded version of a router circle jig. The router is not attached to the circle base with screws but adjustable bearings. This allows the router to rotate freely on the base. The router always remains in the same position and there is no need to worry about the cable anymore.
The router circle cutting jig is designed for cutting smaller circles (from 10 mm to 310 mm in diameter) and can be used both with corded and cordless trim routers. Also, any type of hand router can be used, since the router is not fixed to the base but gripped by adjustable bearings.
I built the circle jig in a few hours. As for the material, I used birch plywood and MDF.
This is an easy project for beginning woodworkers and it is a great jig for a trim router. If you want to cut precise circles in wood, then this circle jig will help you with that. Besides, the material doesn’t cost much and you will see how often you will use it.
Router Circle Cutting Jig DIY Video
Watch the video below, if you want to see and learn step-by-step how to make a universal circle-cutting jig for both corded and cordless palm routers.
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Table of Contents
- Router Circle Jig Video
- Router Circle Jig Plans
- The Material you will need
- General Questions
- What router bit to use to cut a circle?
- How to make a Router Circle Cutting Jig (with Bearings)
- Step 1: Build the Base
- Step 2: Make Bearing Mounts
- Step 3: Make an Adjustable Slider
- Step 4: Make a Test Circle Cut
- Step 5: Add a Self-adhesive Scale Ruler
- Router Circle Jig Video
- How to Cut a Circle with a Router Circle Cutting Jig
*Safety is your responsibility. Make sure you know what you’re doing and take all necessary safety precautions while working with power tools. Safety comes first!
Material needed to make a Router Circle Jig
Material – Birch Plywood, MDF
Router circle jig – base plate
Plywood – 350 mm x 120 mm x 6,5 mm
MDF – 210 mm x 50 mm x 6 mm
Router circle jig – adjustable slider
Strip – 115 mm x 15 mm x 6,5 mm
Check all the Tools I Use
Tools:
Circular Saw – https://amzn.to/4aMD0xg
Hand Drill – https://amzn.to/3HqLEnH
Trim Router – https://amzn.to/3HbQcOg
Spring Clamps – https://amzn.to/41Nuh9D
F-Clamps – https://amzn.to/48ArzY1
Punch Kit – https://amzn.to/41NpzZv
Chisels – https://amzn.to/3tHNJrT
Other:
Wood Glue – https://amzn.to/48ltKhJ
Epoxy – https://amzn.to/3tJ5R4L
Drill Bits – 6mm, 4mm – https://amzn.to/48Kaaf7
Forstner bits – 20mm – https://amzn.to/3Hd1aDb
Double-Sided Woodworking Tape – https://amzn.to/3tPMGpM
Sandpaper Sheets – https://amzn.to/41OMx2p
Adhesive scale ruler – https://amzn.to/3TTjGZb
Aluminum flat bar, Brass rod 4mm – https://amzn.to/48IoQLD
M6 Bolts, M6 Washers, M6 nuts
M6 Wing nut, Wood screws, M6 Bearings – https://amzn.to/41PodgQ
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How is this Router Circle Jig Different?
Typically, when using a standard router circle cutting jig, you need to attach the router to the jig with screws. This Router Circle Jig comes with a different design – it features three mounted bearings on its base. So, when you need to mount the router onto the jig, you simply place it between the bearings and adjust it as needed.
A plus of this design is that you can reuse the circular base almost every router comes with. There’s no need to create a unique base for this jig.
Another advantage is its flexibility with both cordless and corded routers. If you’ve used a corded router with a standard circle jig, you know how the cable can get in the way, needing adjustment with every pass you make. However, this circle jig design tackles that problem. The router stays in the same position throughout the cut, eliminating the constant need for cable adjustments.
What router bit to use to cut a circle in wood?
1. Straight bit
A double flute straight router bit is one of the basic router bits that can be used to cut a circle in wood. To cut a circle, turn the router slowly and gradually trim the individual layers of the material. That will prevent the bit from getting burned and the resulting cut will be clean. If used correctly, you can achieve great results with this bit.
When routing the blade of a straight bit is in less constant contact with the material since the bit tends to chop straight into the stock instead of slicing off the material. The blade of the bit touches the material along its entire edge, which is why it is necessary to take less of a cut and don’t feed as fast to prevent the bit from breaking.
Also, pay attention to the router’s rpm and the speed and depth of the cut to prevent the bit from burning, and possibly breaking. Chips and sand are not easily pulled up from the cut and it’s good practice to continuously clean the cut while using a straight bit.
2. Spiral bit
A spiral upcut/down cut router bit is the best router bit to cut circles in wood. The shape of the bit ensures more constant contact with the material. The blade of the bit touches the material only in several places along its length which reduces the chance of the bit being destroyed or burned.
The spiral shape of the bit provides a nice chip clearance and pulls up the chips and the dust from the cut more easily. Spiral router bits are the most expensive than straight bits, but typically they perform better and they ensure better results.
Let’s start building!
The circle jig is made of birch plywood and MDF. I used a thinner plywood board, measuring 6mm, to maximize the use of the bit length as much as possible.
Different types of hand routers can be attached to the jig. The router is not directly fixed to the cutting base but secured with bearings. Mounting and dismounting a router is very quick and there are no delays in setting the jig up.
The other benefit is that the bearings secure the router in place but the router can freely rotate on the spot. That allows to easily cut circles preventing the cable of the router from getting in the cut path or getting tangled up.
Router Circle Jig parameters:
- Cut circles from 10 mm to 310 mm in diameter
- Easy and quick setup
- Scale ruler for precise setting of the circle diameter
To build the router circle jig you will need a circular saw, a trim router, and a hand drill.
NOTE: The circle jig will work with router bits of different sizes but you will get the best results if used with one specific bit size. I am using a 6mm router bit.
How to make a Router Circle Cutting Jig DIY (with Bearings)
Step 1: Build the Base
Measure and cut pieces for the circle base – plywood piece (350 mm x 120 mm x 6,5 mm), MDF piece (MDF – 210 mm x 50 mm x 6 mm). Together they create a t-slot for the adjustable runner that sets the diameter of the circle.
To cut all the parts I was mainly using a circular saw with a circular saw straight edge guide and a circular saw track, though a jigsaw would work as well.
1. Cut a slot in the plywood piece
Cut a slot along the centerline of the plywood base piece (15 mm x 265 mm). Use a jigsaw with a jigsaw guide or a router with a dado guide to cut a precise and clean slot.
2. Cut a slot in the MFD piece
Cut a slot along the centerline of the MDF base piece (6 mm x 190 mm). Also, trim off a few layers of the material on one side of the MDF piece for the scale ruler – 1/2mm is enough. The width of the slot is equal to the width of the scale ruler.
Glue both pieces together and secure them with screws.
NOTE: It is important that both slots are aligned. Draw lines on the pieces and use them as guides.
Step 2: Make Bearing Mounts
The position of the mounts can differ depending on the router. I am building this circle jig primarily for a Dewalt D26203 Trim Router. The circle base plate delivered with the Dewalt router has a diameter of 115 mm.
You can either drill the holes specifically for your router base or if having multiple routers, you can make a universal circle base plate that can be used with each of the routes and would fit the circle jig.
Drill three 6mm holes in the base. Carve a hexagon around the holes for the nuts (Insert an M6 bolt in the hole, outline the bolt’s head and use a chisel to carve out a hexagon). After insertion, the nuts must be completely flush with the surface.
Use epoxy to fix the nuts permanently in the holes.
NOTE: To drill the holes for the nuts it is possible to use a Forstner bit as well. Though I wouldn’t recommend it. The 6mm plywood board is not thick enough and you can go easily through it.
Attach the bearings to the base and adjust them as necessary so they fit tightly around the circular base plate. (The bearings have an inner diameter of 8mm so they can be easily adjusted if used together with a 6mm bolt).
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Step 3: Make an Adjustable Slider
Cut a plywood strip (115 mm x 15 mm x 6,5 mm) and drill in 3 holes along the centerline. The inner hole has a diameter of 6mm the outer holes 4mm.
1. Inner hole – tightens and fixes the slider in position (either with a wing nut or a wood knob)
Carve a hexagon around the center hole and insert an M6 bolt in. Use epoxy.
2. Outer holes – the closer one to the center serves as a pivot point, the other as a readout of values on the scale ruler.
First, insert a brass pin in the hole closer to the router bit and let 4mm stick out – this pin serves as the pivot point (remember, the pin points down into the cut material). Mount the slider in the slot and secure it with a wing nut.
After mounting the slider add the scale value reader.
Step 4: Make a Test Circle Cut
Make a test circle cut before attaching the scale ruler. Cutting a circle will serve as a reference for the placement of the ruler.
Mount the router on the circle cutting jig and set a circle diameter to 100 mm (I am counting with the outer edge of the router bit). Cut a circle and measure how much you differ from the set value.
Step 5: Add a Self-adhesive Scale Ruler
Once finished with the test cuts, keep the settings and tape a scale ruler to the base of the circle jig.
This is what the finished router circle cutting jig looks like. You may not be using it daily but it is definitely one of the top 5 woodworking jigs for a router. Surely pays off to have one in the shop.
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How to Setup and Use a Router Circle Jig with Bearings
The provided steps below describe how to set up and how to use a Router Circle Jig to cut a circle in wood. Take all safety precautions when using a router.
How to Cut a Circle with a Router Circle Cutting Jig
Mounting the Router:
- Begin by mounting the router on the circle jig between the bearings, ensuring it’s secure with screws. This step is fundamental as a firmly mounted router will grant you the control and stability required for a precise cut.
- The bearings provide a snug fit, reducing the risk of the router shifting or wobbling during the cutting process.
Inserting the Router Bit:
- Next, insert a router bit into the router. The choice of the bit is crucial as different bits are designed for various cutting tasks. Ensure the bit is tightly secured to avoid any mishaps during operation.
Setting the Circle Diameter:
- Set the desired circle diameter by adjusting the slider and the pivoting point on the jig. This adjustment is where you get to define the size of the circle you wish to cut.
Preparing the Stock:
- Drill a hole into the stock where you wish to cut the circle. This hole is where the pivoting point of the circle jig will be placed, acting as a center point for your circular cut.
Positioning the Circle Jig:
- Now, place the pivoting point of the circle jig into the drilled hole in the stock.
Cutting the Circle:
- Finally, cut the circle with the router. Move steadily at a consistent pace to maintain a smooth cutting edge.
