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DIY Trim Router Circle Jig

This document describes a simple 3D printed jig for cutting circles with a trim router. The jig uses a slider mechanism attached to a base that can be adjusted to set the radius of the circle. It is designed to work with a 7/16" guide bushing and 1/4" spiral cutting bit. Assembly instructions and usage guidelines are provided. Files to 3D print the parts are linked.

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AntonioPallone
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55 views

DIY Trim Router Circle Jig

This document describes a simple 3D printed jig for cutting circles with a trim router. The jig uses a slider mechanism attached to a base that can be adjusted to set the radius of the circle. It is designed to work with a 7/16" guide bushing and 1/4" spiral cutting bit. Assembly instructions and usage guidelines are provided. Files to 3D print the parts are linked.

Uploaded by

AntonioPallone
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Trim Router Circle

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updated 11. 1. 2023 | published 11. 1. 2023

Summary
Simple circle jig for a trim router

Hobby & Makers > Tools

Tags: circle circlejig dewalt router ryobi trimrouter


circlecuttingjig milwaukee portercable

I designed a simple circle cutting jig to be used with a trim router for
cutting small circles and holes. This design is meant to be used with a
7/16" (11.1 mm) OD guide bushing and 1/4 inch spiral cutting bit. The
cutting capacity is circles from ~3" to ~13" in diameter. Using the guide
busing instead of fixing the router directly to the base prevents the cord
from getting twisted around as the the router can pivot in the hole. Use a
centering tool to ensure the base place hole is centered with the collet.

Printing Instructions

• Set Layer Height as desired, I used 0.3 mm


• Use 4 perimeters
• Use 25% infill
• Material of choice

Print files in the orientation as downloaded. Use a support enforcer in the


recessed hole on the slider for a cleaner print. Tolerances of the parts are
very tight to minimize any slop, scale and adjust at risk of the parts not
filling together well. Using a well tuned printer, you should not have any
issues. All parts can be printed at the same time.

Required Hardware

• M4 nut
• M4x16 screw with low profile head
• Metal washer (large enough to span the slot in the body)
• 2.5 mm metal pin (I used a nail and cut it to size)

Assembly

• Look through the pictures to help understand how the parts fit
together
• Glue the M4 nut into the knob and allow to dry
• Thread the M4x16 screw into the hole in the slider, this is a tight fit to
prevent it from coming out unintentionally. The screw should enter
through the recessed opening (bottom) of the slider
• Insert the metal pin into the smaller hole on the slider with the body
of the pin protruding down from the bottom. I hammered the nail in
from the top then cut it flush. Do your best to ensure the pin is square
to the body of the jig. The length of the pin is up to you but I
recommend the pin extends at least 3/8" below the bottom of the
slider
• Place the slider into the slot of the body with the threads of the screw
protruding above the body of the jig
• Place the washer over the screw and thread on the knob, tightening
to lock the slider in position. The top of the slider should be recessed
below the top of the jig to allow the washer to adequately clamp onto
the body of the jig

Using the Jig

To use the jig, drill a hole (or make a hole with a nail of the same diameter
as the nail used for the pin) in center of desired circle the same size as the
pin, careful not to drill through the material if you want a blemish free
circle on one side. Set the slider to the radius of the circle and secure it
using the lock knob. Make sure the slider is secured well otherwise it will
slip and the cut will not be as desired. Place the guide pin into the hole.
Install the guide busing onto the base plate of the router and install a 1/4"
straight cutting bit into the router with the bit retracted into the router.
Place the guide bushing into the hole on the jig, power on the router, and
slowly lower the bit into the work piece, and lock the depth. Be careful not
to be too aggressive with the depth of cut. Guide the router on the jig to
cut the circle, lowering the bit as needed for each pass. Make sure the
router comes to a complete stop before trying to remove the jig from the
work piece or router from the jig.

The guide markings on the bottom of the jig are in 1/2" increments and
account for the 1/8" offset needed for a 1/4" bit. The offset is needed to
account for the bit radius, ensuring the circle is cut at the desired
diameter. To cut a hole, you need to subtract 1/8" (when using a 1/4" bit)
from from the radius and set the slider accordingly. For best results use a
tape measure to set the slider.

The slider can be rotated 180 degrees to aid in setting desired


measurements.

Use at your own risk.

Model files
router-circle-jig-overview.stl

circle-jig-body.stl

circle-jig-slider.stl

m4-knob.stl

License 

This work is licensed under a


Creative Commons (4.0 International License)
Attribution—Noncommercial—Share Alike

✖ | Sharing without ATTRIBUTION


✔ | Remix Culture allowed
✖ | Commercial Use
✖ | Free Cultural Works
✖ | Meets Open Definition

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