If you intend to work on different woodworking projects, one of the techniques you must learn is cutting circles in wood materials. However, making a perfect circle isn’t easy and could result in disaster when not executed properly.
Rather than relying on luck, let me discuss the different ways to cut circles with tips and tricks to ease your hands-on experience.
Method #1: Using a Table Saw
You may not know, but table saws can cut circles well. Most woodworkers opt for the table saw method because this power tool can handle thick wood materials. It’s also safer than other power tools, making it suitable for newbie users.
- Step 1: Make a zero-clearance edge by placing a runner over ¾-inch plywood. Let the sled run through the table saw blade to remove excess wood pieces.
- Step 2: From the sled, create a line perpendicular to the cutter that’s halfway to the front edge.
- Step 3: Create a pilot hole on that line before drilling. It should match your desired radius for the circle you want to make. You can use a headless finish nail as a pivot pin.
- Step 4: Take your square blank and find its center point. Drill a small pilot hole in that spot and mount the material in the pivot pin you attached to the circle-cutting jig.
- Step 5: Cut off the four sides of your wood blank by sliding the circle jig back and forth with the table saw blade.
- Step 6: Continue to cut the wood’s edges until the material is close to the perfect circle you intend to make.
- Step 7: Align the blade’s tip on the line you traced on the plywood jig. You’ll need to lock the jig into position, so I suggest using a magswitch.
- Step 8: Spin the wood into the cutter in a clockwise direction until the final circle reaches its perfect radius.
Method #2: Using a Router
When it comes to making large circles on wood, I’ve found that using a router table or plunge router is your best bet. In my experience, this method consistently delivers the cleanest and most accurate results compared to other circle-cutting techniques. You can also count on it to cut small circles.
Cutting in a Router Table
- Step 1: You’ll need to create a jig that fits your router table for extra safety. If you don’t know what it is, this material is simply a wooden board with an attached fence.
- Step 2: Create a pivot point to create an opening for the router’s bit. You can do this by drilling screw holes into the material and the jig.
- Step 3: Put the jig on the table and lift the bit to fit the drill hole you created. You must turn off the tool during this step and clamp the jig firmly on the table.
- Step 4: Your workpiece should be placed firmly into the jig, making it rotate freely. However, bearing contacts with the router bit should be allowed.
- Step 5: The fence’s right corner should be tightened, but leave the left side as is. So when you turn the router on, move the fence’s left corner away from the operator and slowly drive the material into the bit.
- Step 6: Tighten the left corner and let the workpiece spin into the router in a counter-clockwise direction.
Method #3: Using a Bandsaw
Since bandsaws have narrow blades, experienced woodworkers should have no problem creating circles without a circle jig. However, a circle-cutting jig should be on your tool list if you want to cut circles in wood faster with little to no risk of inaccuracies.
Start by crafting your own jig; cut a runner from wood that fits the bandsaw’s miter slot like a glove.
And then, put the runner underneath the plywood to help it stick out on the bandsaw’s table. Mount the sled forward, straight into the bandsaw. Cut through the kerf, and halt when the blade is halfway through the cutting depth. Trust me, this step helps keep everything aligned.
Create a mark perpendicular to the kerf line tip, and get your handheld drill to make a small pilot hole to match the circle radius you intend to make. A finish nail can serve as an ideal pivot point; I’ve found it gives a cleaner result.
After drilling the pilot holes, place the square blank into the jig’s pin. If you can, use a ¼-inch blade for best results. Cut the material until you cannot push the jig forward any longer. Continue spinning the blank clockwise up till you get a perfectly round circle.
For a more accurate cutting result, don’t forget to check if the blade tension, guiding blocks, and bearings are set properly.
Method #4: Using a Circular Cutting Jig
As I said before, a circle-cutting jig can assist your chosen tool in cutting a circle according to your size requirement. The jig creation will depend on which cutting machine you’ll use because it has to match the tool’s components, like a miter slot.
Method #5: Using a Jigsaw
It doesn’t matter if you intend to cut smaller or larger circles because jigsaws can cut straight lines and tight curves. Here are some of the methods you can try using this tool.
Measure and Draw the Circle
For this method, you must mark the measurements in the wood blank. Utilizing a beam compass [1] is the best way to do this. It’s a tool to secure the circle’s radius measurement.
Alternatively, you can cut a circle using a string with a pencil and a finish nail. Although it’s cheaper, getting a perfect result will be difficult with this method. I only recommend it for making smaller circles.
Do the Freehand Cut
Cutting a circle without any assistive tools or strict measurements can make anyone a bit nervous, but you can opt for this process if you don’t need a perfect result. You can start at the material’s cutting edge until the blade reaches the marked lines.
Continue the multiple passes of cutting and sanding till you get the right diameter according to your woodworking needs.
If you’re making a circular hole in the wood material, I suggest drilling smaller holes for the blade and using the drill bit to cut the inside edge of the circle.
Interesting read:
Using a Cutting Jig
If you seek accuracy, there’s no better option than using a cutting jig. While you can buy one, remember that it’s only a thin ½-inch wood strip with 4 to 5 inches of width. Because of this, they’re easy to create.
To use it, you can place the jigsaw at the jig’s edge aligned with the center point of the material at the other end.
Method #6: Using the Router Circle Cutting Jig
Since these tools are adjustable, you can count on them to deliver the best results no matter what circle sizes you’re trying to achieve. You can use it along with plunge routers, and here’s how you do it.
- Step 1: Buy or create a circle jig aligned with the router’s size. For visual reference, the jig can be made out of ¼-inch plywood.
- Step 2: Get your router’s base plate and use it to mark the holes at the jig’s edges.
- Step 3: Countersink the screw heads to keep the router attached to the plywood.
- Step 4: Drive a bit into the jig before removing it from the router and making a bigger hole.
- Step 5: Drill a pilot hole in the wood blank’s middle point aligned with the jig’s hole.
- Step 6: Run the router clockwise until you make a full circle path.
- Step 7: Adjust the plunge settings ⅛-inch deeper every revolution until a perfect circle is achieved.
Method #7: Using a Jigsaw, Router Jig, and Flush Trim Bit
While this method also includes the usage of jigsaws and router jigs, it differs because you’ll have to utilize a flush trim bit for this process.
- Step 1: Take the up-cut bits for two to three circle revolutions before taking the jig out of the picture.
- Step 2: Grab your jigsaw to cut a circle with a groove guiding the entire process. Once done, you’ll notice that it’ll leave a lip around the circle.
- Step 3: Put flush trim bits in your router and plunge it. You should also align the bearing with a clean lip previously left by the tool.
- Step 4: Guide the router in a counterclockwise direction until you reach the lip. Don’t stop going around until you’re left with a perfect circle.
Method #8: Using a Bandsaw Circle Cutting Jig
Another method you can consider is using a circle-cutting jig with bandsaw tools. Besides the cutting machine, you only need a ¼-inch blade, ¾-inch plywood, stop blocks, and a runner.
- Step 1: Cut the hardwood material to create a jig. The size should align with your bandsaw miter slots.
- Step 2: Attach it under the plywood and ensure it overhangs on the right side of the bandsaw table.
- Step 3: Move the sled toward the tool and slice the kerf. Halt the cutting operation halfway through the cut.
- Step 4: Add the stop blocks under the table’s edge.
- Step 5: Mark the line that aligns with the kerf line’s tip. After that, make an initial hole in that spot to make room for the pin.
- Step 6: Make the same hole size in the wood material and mount it on the jig’s pin.
- Step 7: Cut until the blade can’t push further against the table. From there, rotate the wood clockwise to cut a circle.
Method #9: Using a Flexible Drill Bit for Circle Cutting
The possible alternative method you can consider if you don’t have the right hole saw size is using an adjustable drill bit. At first glance, it looks like a compass, but cutting a circle in wood is possible due to its sharp blade tip.
Instead of a drill, these tools are used in a drill press. For safety’s sake, I highly advise keeping the RPM setting at 500 or lower. This measure not only ensures your safety but also enhances the quality of your circular cuts.
Method #10: Cutting with No Centerpoint Circles With a Hole Saw
If your project requires no center points, hole saws should fulfill your needs. All you need to do for this method is lock the location and chuck the area you want to drill.
Supplies Needed
Besides the hole saw, you must buy an arbor and pilot bit in your nearest home improvement stores. These materials connect pieces and guide the tool during the process.
Read Your Hole Saw and its Attachments
Check the hole saw’s interior diameter if you need the circle cut out. You can consult the fine print for its interior size and the attachment installations for more efficiency and accuracy.
Position the Wood Securely
These tools carry massive torque, so it’s crucial to clamp the material before the cutting process. Don’t forget to leave a space below the material to prevent unintentional cutting or accidents.
Put the Pilot Bit at Circle’s Center
Draw a visual of the circle and find its center. It’s the spot where you’ll drill the pilot bit for the next step.
Start Drilling the Wood
The bit will lead the hole saw into the wood’s surface during the drilling. Hold the tool as firmly as possible to achieve stability and better results.
Halt and Restart if the Hole Saw Sticks to the Wood
Stop the operation immediately if you notice the drill binding to the material. Work through the board slowly and as lightly as possible when you restart the tool.
Flip the Wood Midway to Prevent Blow Out
You may not know, but continuous cutting can cause the hole saw to blow out. If you don’t want this to happen, flip the material over before sawing again.
Take Out the Circle from the Wood
As long as you’re careful, you can use your fingers to pull out the circle inside the hole saw. You can also get a flat-blade screwdriver and push it out.
Disadvantages of Using This Tool
Can Overheat
If you can, don’t put too much pressure on the tool. In my experience, it’s crucial to clear away the accumulated sawdust periodically. This small action can go a long way in keeping the tool cool and functioning optimally.
Shallow Cut
Hole saws have limited depth, so handling thicker materials is not where they shine best. A helpful workaround I’ve found is pairing the hole saw with a drill, which can enhance the tool’s depth capability.
Back Splinters
The back side of the hole saw cut isn’t the cleanest. You can remedy that by placing scrap wood underneath the material to avoid a blowout.
Read Next: CutList Optimizers Review
Method #11: Using a Belt or Disc Sander
The last method you can do is to sand the material into your desired circular shape. This method is particularly useful when working with thicker wooden materials, as it provides greater control and stability compared to handheld tools. However, you’ll need to cut the wood first to get the perfect outcome.
- Step 1: Start cutting the material’s corner. The more parts you cut, the less you’ll sand.
- Step 2: Drill a hole in the middle of the workpiece and another one on a scrap board.
- Step 3: Clamp the scrap board to the table where your disc sander is. Ensure that only the front face of the board is clamped.
- Step 4: Feed the board’s backside into the sanding tool until it’s in contact with the sander. After that, sander each corner evenly.
Cutting a Wooden Circle vs. Cutting a Circular Hole
Cutting a circular hole and needing circular wood as a material are different outputs that require varying methods. Remember that not all tools can do both, so it’s best to think your choices through.
(For other wooden projects, here’s how you can cut square holes in wood!)
Conclusion
As intimidating as it seems, cutting circles in wood is a woodworking technique you can’t skip to learn.
From my experience, I can assure you that these methods will prove invaluable in the long run, especially if you intend on taking on different projects. After all, doing these techniques will introduce you to a wide range of tools and materials.
You've probably seen his down-to-earth wisdom in USA Today, Bobvila, Family Handyman, and The Spruce, where he has shared commentary and guidance on various woodworking topics.
Robert is the brain behind Sawinery, where he aims to share tips, tricks, and a passion for all things carpentry.
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