DISK ROUND OVER JIG

About: 1945 was a very good year. No, not for wine ... for me. I was born. Yes, I'm old, Father William, but brillig, and my slithy toves still gyre and gimble in the wabe. So let me welcome you to the Little Sho...

Intro: DISK ROUND OVER JIG

I made this jig to safely round over small disk game pieces in my ROYAL GAME OF UR Instructable. I really think it deserves its own Instructable. I have 36 stitches in my wrist from momentarily losing concentration while working with a router. It is called an ACCIDENT. And accidents do happen. They are not called On Purposes. My brother lost most of the fingers on his right hand in a radial arm saw accident. They were able to reattach all but one. He says he can no longer point with that hand --and usually adds: or pick his nose. But that is TMI.

Step 1: MATERIAL

I used a piece of scrap from my lumber cart. It was 3/4" x 4 1/2" x 10 1/2" of some sort of hardboard or composite board or pressboard. Whatevah!

Step 2: TOOLS

I only used a few tools for this jig. The miter saw and router table and the drill press. Oh, I used the square to mark the 45s.

Step 3: THE JIG

Drill a hole larger than your router bit. Mark an opening SMALLER than the diameter of the disk you will be routing. This will prevent the disk from being sucked into the router blade along with your finger. Use a square and mark 45° lines emanating from the hole. Clamp the jig securely in place to prevent it from moving. Set the bit bearing to the CENTER of the disk. Route one edge of the disk, flip it over and route the other. Sand.

Step 4: CONCLUSION

With a bit of sanding, you should get a nicely finished piece.

KJ

As usual, all questions answered, all comments appreciated.

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    4 Discussions

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    KellyCraig

    Tip 5 weeks ago on Step 2

    Nice job, kid.

    1) Because router bits get dull and a dull bit can jump, consider putting a little piece of Plexi or similar over where the router bit. That would add a bit of safety in a few different ways. For example, it would limit how much the disk can jump.

    You could layer the plastic, if necessary, so it goes down past the top of your jig and just above the bearing or bushing.

    2) If you wanted to dedicate a bearing to this process, you can remove the bearing and grind off the mount, which would allow you to get the clear shield down lower to the bearing. I've done this with large, 1/2" shank bits to allow me to keep moving the bit over the wood to replicate a siding pattern.

    3) I make small push sticks I use, religiously, around my bandsaw and things that like to eat fingers and such. With a rubberized tip, one could be used to roll the stock across the bit. Examples may be seen on the LumberJocks site at:

    http://lumberjocks.com/projects/105726

    Just modify the ends to your needs for a project like this (over forty years and still have my digits and no war wounds).

    3 replies
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    Kink JarfoldKellyCraig

    Reply 5 weeks ago

    Hi, Kelly, thanks for all the advice--and thanks for calling me kid, but I'm sure I've got a few years on you. Yet, never too old to learn new tricks. KJ

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    KellyCraigKink Jarfold

    Reply 5 weeks ago

    Yep, you do [have a few years on me] and I knew that. My buddy was ninety-four and I called him kid too. After all, there are a lot of us seven and eight [or more] decade kids around.