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Finally back on the saw


Badgerboy

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21 minutes ago, CSull said:

Beautiful, if you dont mine me asking-do you cut the circular part on your scroll saw or some other way?  I have a lot of trouble making my circles perfect on my scroll saw and was wondering if I should use a router circle jig for the circles?

I cut them on my scrollsaw which is challenging due to the size.  I cut both layers at once do they match.  I have devised a plan to cut them using a circle cutting jig and my router with a hole in the backer board but for now I cut them on my ss slowly and carefully. 

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9 hours ago, CSull said:

...  I have a lot of trouble making my circles perfect on my scroll saw ...

If you own a vertical belt bench sander you can make your circles just about as perfect as possible.   The cut panel should be affixed to the backer either permanently, or with double stick tape, before cutting the disk.  I cut out the disk making sure I cut on the OUTSIDE of the line.  Slow and carefully but not worrying if the cut is real smooth. the cut line needs to remain visable all the way arount the disk.  Then, using the table on the vertical belt sander  to get a true vertial edge, you can carefully and gently sand away the waste until the line is just removed evenly all around.   Actually this is easier than it sounds, However, the trick is to keep the disk moving/rotating while the sander takes the material off slowly.

  

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15 hours ago, CSull said:

Beautiful, if you dont mine me asking-do you cut the circular part on your scroll saw or some other way?  I have a lot of trouble making my circles perfect on my scroll saw and was wondering if I should use a router circle jig for the circles?

I used to have the same problem but found the answer. Just cut close to the line leaving enough to see the line. Then go to the disc sander and sand to the line. Really easy and quick. 

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If you want to cut the circle part first, before cutting the insides,  you can double face tape them, and make a jig for a bandsaw if you have one.  then on the backer you may see the center pin  where a small nail tip sits.. but you can cut the outside perfect circle.  There are some real nice plans on YT for adjustable ones so you can cut circles from like 3" out to 3 ft or larger...  but it will easily  handle up to a 20" circle..

I made this one for myself.

 

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