How to cut a perfect 2 7/16" diameter circle...

[Michael Dunn]

Besides a fly cutter, what are my other options. I need this to make templates for making several ZCI's for my BS. To elaborate, I need the cutout, not the remaining hole, to be 2 7/16". Actually, I haven't measured it in a while so I'm recalling that from memory. But you get the idea, right?

[Wade Lippman]

You mean other than a hole saw?

[Richard Jones]

Band saw, disc sander, lathe.............

[Michael Dunn]

You mean other than a hole saw?

Yes. I need the cutout to be 2 7/16" or 15/32"... I can't remember. A hole saw will drill a hole at a specified size. I need a cutout at a specified size. I guess I should try a better quality fly cutter. I think mine sux.

[Michael Dunn]

BS... Nope. I'm trying to make inserts for my BS it's already too dangerous songs I have no insert. Disc sander... Maybe, well, I'd have to cut it out on my BS and then sand it. I don't had a lathe... Yet!!! One day.

[Bill Holland]

Just do some math, measure the outside of the closest size you have & subtract the wall thickness off the holesaw x 2. You may have to buy a metric hole saw to get the one with the right size id you are after. Only other method would be to take a caliper to a hardware or industrial supply house & measure the id. I got a bunch of holesaws nail down what size you need I will measure what I have & let you know what you need to go get.

Bill

[glenn bradley]

I used one of these. You can find them at the BORG around here. You can set it up for outside dimensions or inside dimensions by reversing the cutter.

[Bruce Wrenn]

I would use a router and trammel. Mine is "micro adjustable." Cut a sample, measure it and adjust trammel. Remember you only need to move trammel HALF of the difference between actual and desired size.

[Ole Anderson]

I think you already have the answer, get a better fly cutter, one with a 1/2" shank, but only if you have a drill press. As Glenn suggests. Rotate the cutter so the bevel is on the outside of the circle. You will still have a hole in the center. I have used them for cutting masonite, solid wood and 1/4" aluminum plate.

A router and a trammel is a great way to cut a circle, not sure how you would do a radius of 1-7/32" with this method.

[Roger Rayburn]

This guy did what you are saying you need to do. Good video. http://www.garagewoodworks.com/video...7&category=all

[Keith Outten]

Unless you just want to make them yourself there is a large group of people here who own CNC Routers who can make the inserts for you, probably 25 of them in five minutes of machining time and they would all be the perfect diameter and thickness. If your table insert needs a step no problem as long as you can measure it accurately. The saw access cut can also be cut to the width you require.

Use our Friends of THe Creek Directory or post a classified ad, you may find someone in your area.
.

[Michael Dunn]

This guy did what you are saying you need to do. Good video. http://www.garagewoodworks.com/video...7&category=all

That looks great!!! Except a bit dangerous to cut that close to the blade by hand without a table insert.

[Steve Milito]

Hobbyist loudspeaker makers use a router jig to make holes for tweeters and midrange speakers. It should work for your app.

http://www.jaspertools.com/productsd...Circle%20Guide

[Wade Lippman]

This guy did what you are saying you need to do. Good video. http://www.garagewoodworks.com/video...7&category=all

Guy's crazy. I bought 3 from Grizzly for a couple bucks each. Beats spending an hour making one.
And if you want to make them yourself, use a larger piece of wood and get the thickness right on a planer.
Then test the diameter as you sand it so you don't have to nail a brad in the side.
Geez.

[Perry Holbrook]

You do realize you can use a piece of scrap, maybe plywood, to make an auxiliary table, with no insert and use the saw?

Perry