Replies

1. 
   johnhardy | Jan 21, 2003 10:28pm | #1

   If you cut a sample in thin template material, you could then use a router with a bearing to clean up a hole that you rough cut with a jig saw. Should be extremely fast and painless.

   John

2. 
   MPHarper | Jan 21, 2003 10:47pm | #2

   I second the vote for a template guided router.  It will leave you a nice clean hole without any need for sanding.

   Matt-

3. 
   Andrew | Jan 21, 2003 11:02pm | #3

   If you have a plunge router you could skip the jig saw and template step and just use a circle cutting jig with your router. use a spiral bit and you should be able to do it in a few passes or less depending on your router, the wood and bit size.

4. 
   BG | Jan 22, 2003 12:02am | #4

   Sunne,

   I vote for the router method too.  However, Greenlee electric has a 6" hole cutter..that may be an option you'd like to consider.  Also, just cause its an option, the circle cutting tool for the drill press might be something you'd take a look at too.  good luck 

1. 
   mcsquare | Jan 22, 2003 04:19am | #5

   I have been pouring over all my back issues of woodworker supply magazines and wouldn't you know I found just the right tool for cutting large holes perfectly. It's a circle jig made by Jasper and is available in three models depending on the size of the hole/circle you want to cut. It works with a plunge router and an (up spiral) router bit (1/4") and sells for $49.95. Check it out in the Woodworkers Supply Catalog on page 20.Thanks for all your imput, I really appreciate your consideration and interest.

   Give me a shout if I can ever be of assistance to any of you. Been working with wood, metal, and glass for over 40 years.Be glad to help in any way I can.

   Andrew Sunne McDoneld

   Master Carpenter

5. 
   JackLindsey | Jan 22, 2003 11:35am | #6

   I use a router with a trammel baseplate. Cuts perfect circles of almost any diameter with little effort. Takes about an hour to make the baseplate and you should be able to use scrap material for most of it. Works best with a plunge router. See page 39 of Router Magic by Bill Hylton.

   Jack