Bandsaw Circle Cutting Jig | How to Build Tutorial

Ashley — Sat, 17 Nov 2018 03:56:20 +0000

Learn how to make an adjustable circle cutting jig for your bandsaw in this step by step DIY tutorial.

How to build a bandsaw circle cutting jig. Make repeatable perfect wooden circles!

Hello everyone, today I’m sharing how to build a circle cutting jig for your bandsaw. This is a really easy shop project that will make cutting circles a breeze. My bandsaw circle jig is largely inspired by George Vondriska’s bandsaw circle cutting jig. I loved the adjustable dovetail slider feature in his jig and had to incorporate into my jig.

Let’s get started!

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Tools and Supplies

The following items are some of the tools and supplies I gathered to create my bandsaw circle cutting jig:

Tools

Supplies

1/4″ – 20 Threaded Inserts
1/4″ – 20 Thread Size Star Knob
Sticky Measurement Tape
3/16″ dowel
1/2″ Plywood (I used scraps)
Scrap hardwood for miter slot runner and stop block
Double sided tape
Rare earth magnet
E-6000 Glue
Wood Glue

How to Video Tutorial

Watch the how to make video below or continue reading for the written tutorial.

How to Make a Circle Cutting Jig for the Bandsaw

The bandsaw circle jig is a quick weekend shop project that can be made using scraps from your woodworking pile.

Step 1: Cut a piece of plywood for the base of circle jig

Cut a piece of plywood for the base of your bandsaw jig. My circle jig was created to fit on the Rikon 10-305 bench top bandsaw and is roughly 11″ x 16″. Your dimensions will vary based on the size of your bandsaw and on the size of the average circles that you want to create. The maximum sized circle that I can cut with my jig is just shy of 16″ radius.

Step 2: Cut a sliding dovetail

Cut a second piece of plywood to match the dimensions of your circle jig base.

Make a mark where the bandsaw blade will line up and from that point mark two lines: an inch above and below the initial mark. This section will be the adjustable sliding dovetail.

Cut along the lines with a 30 degree bevel on the table saw to create the sliding dovetail.

Sliding dovetail cut at a 30 degree bevel

Step 3: Assemble the jig

Glue the top sides to the base of the circle jig. First glue and clamp one side. Place the sliding dovetail with a card on each side before gluing and clamping the second side. This will ensure that the dovetail has room to freely slide in and out.

Using playing cards as a shim for the sliding dovetail

Once the glue dries, trim up the edges of the jig on the table saw.

Step 4: Create a stop block

I used a scrap piece of oak and attached it to end of the circle jig. You’ll want to ensure that the stop block allows the jig pivot dowel to line up with the front of the bandsaw blade.

Step 5: Attach a runner for the miter gauge

Attaching a runner for the miter gauge slot

Using more scrap oak, I ripped a piece of oak that matched the width of my bandsaw’s miter slot and attached it to the base of the circle cutting jig.

Step 6: Install magnets for jig stability

At this point I noticed a had an imbalance issue with my bandsaw jig. I installed a small rare earth magnet to the base of my bandsaw jig. It was a magnet that purchased a long time ago so I do not know what the strength rating was, but it did the trick in resolving my jig’s balance issue.

Step 7: Create clamping mechanism for the sliding dovetail

Drill a 5/16″ hole in the sliding dovetail channel. Install a 1/4″ threaded insert. Screw in a 1/4″ star knob to clamp the sliding dovetail into place.

Using a threaded insert and a star knob for the sliding dovetail’s clamping mechanism

This was my first time using threaded inserts. It was a breeze and adds a nice touch to the project.

Step 8: Install dowel for circle pivot point

Drill a 3/16″ hole and insert a 3/16″ dowel. This is the pivot point for the wood blanks.

Step 9: Install sticky measurement tape

This final step is a really nice to have: installing sticky measurement tape. To install the tape:

Lock the sliding dovetail into place
Cut a circle on the bandsaw with the jig
Measure the diameter of the circle
Line the sticky measurement tape up with the end of the sliding dovetail
Cut off any excess tape

Applying sticky measurement tape to indicate the radius of the circle

Now you’re adjustable bandsaw circle jig is ready for action. Enjoy!

Cutting a circle with the bandsaw circle cutting jig

Bandsaw circle cutting jig on the Rikon 10-305 bench top bandsaw

How to cut a circle without drilling a hole

More often than not you’ll probably want to cut a circle without damaging the surface by drilling a hole for the pivot point. You can avoid marring the surface of your circle by first cutting a sacrificial circle.

Attach a wood blank to the sacrificial circle using double sided tape. Now you can cut a circle from the wood blank without damaging the surface.

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How to build a bandsaw circle cutting jig

Hope this post inspires you to build a circle cutting jig of your own. It’s a huge time saver over using a router and much more accurate that cutting a circle with a jigsaw.

Here’s a fun little gif of the bandsaw jig in action!

Using my bandsaw circle cutting jig to create a round gradient cutting board

The post Bandsaw Circle Cutting Jig | How to Build Tutorial appeared first on Handmade with Ashley.

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