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Building a circular cutting device for the band saw

The band saw is a versatile device that is part of the standard equipment in many workshops.

With a band saw individually sized circles can be cut out of wood. In order to cut exact lines, you need a steady hand and a lot of tact or you simply build your own circular cutting device and cut perfect circles easy-peasy from now on with your band saw. Interested? 

Here´s how it´s work: 

Material Tools
Wooden panels Table saw or jig saw
T-Nut Profile Band saw
T-Nut Grinding machine
Countersunk screw M6  
Nail  

Step 1: Cutting the plates

I´m a friend of residual wood utilization, therefore I make use of the wood I find in my wood storage. Alternatively, you can use plywood or textured coated boards.

You can then set the size of the plates after your own preferences. Take note: The larger the device, the larger circles or rings you can cut. I´ve chosen a OSB plate with a thickness of 15 mm as base plate and cut it to 340 mm x 440 mm.

For the upper plate we take a 24 mm thick plate and cut it in the same size and then cut it in two identical pieces. After that we grind the edges and if necessary also the plates.

Step 2: Attaching the T-Nut rail

In the second step we adapt the T-Nut rail. You can find it in a good hardware store or the Internet. Of course, you could leave the top plate completely and use a router to fix the T-Nut, that would be cheaper but not as stable as the first alternative.

Afterwards we screw rail and glue the boards together.

Step 3: Making the stop block

Next we build a stop log out of hardwood in the size 50 mm x 20 mm. This should run neatly in the guide of the groove and not be higher than the top of the device. The block also requires a hole with a countersink for the fixing screw.

In addition, the stop block needs a hole where we hit a small nail through. This is needed as a pivot for our circle to be cut.

Step 4: Cutting the groin

Afterwards we need a groin that fits in our table, the work piece receptacle of our band saw. The height of the groin shouldn't be taller than the length of the band saw table.

Step 5: Aligning and bolting the device together

Now we align the device parallel on the work table, so that it barely touches the saw blade and the center of the T-Nut just starts in front of the saw teeth.

We draw a line at the bottom of the base plate where the guide rail should be located and after that we screw them to it. Now we can easily change the position of our device on the band saw.

Step 6: Attaching the stop groin

For the correct and easy positioning on the work table we now need a stop groin which prevents the device from moving backwards while sawing. We locate the groin so that the saw blade begins in the middle of the T-Nut bar.

Step 7: The finish

Finally, we can adjust our stop block with the work piece receptacle to cut out our first circle. I chose a diameter of 200 mm and set the block therefore to 100 mm.

Now we put the board, which we want to cut, on our device. We have previously provided the board with a hole in the middle. After that we push our device slowly in the direction of the saw blade and then start with the circular cut.

Of course you could set the diameter even smaller to cut a ring, but then you have to glue the incision site.

I hope I could inspire you a little bit again

Your Einhell Harry

AuthorHarry Früchtl
Reading time10 minutes

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