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How Do I Cut Round Coasters?

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Forum topic by Mean_Dean posted 1082 days ago 3085 views 0 times favorited 26 replies Add to Favorites Watch
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Mean_Dean

1386 posts in 1781 days


1082 days ago

I want to make a set of round coasters (to set a beverage cup on), and can’t really think of a good way or jig to do the outside cut. I want them to be perfectly round, not cut on a bandsaw and sanded.

Does anyone know of a good jig that’s quick and easy to make and use? Any help will be greatly appreciated!

-- Dean


26 replies so far

View PurpLev's profile

PurpLev

8476 posts in 2282 days


#1 posted 1082 days ago

template and router table

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View willie's profile

willie

464 posts in 1088 days


#2 posted 1082 days ago

You could turn a cylinder on the lathe and slice off coasters on the tablesaw.

-- Every day above ground is a good day!!!

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Mean_Dean

1386 posts in 1781 days


#3 posted 1082 days ago

PurpLev,

Thanks for responding. Router table is no problem, but how do I get the template perfectly round to cut an outside curve?

-- Dean

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TheDane

3741 posts in 2297 days


#4 posted 1082 days ago

You could turn a block of wood to the diameter you want your coasters to be on the lathe, then slice to the required thickness on the bandsaw.

—Gerry

-- Gerry -- "I don't plan to ever really grow up ... I'm just going to learn how to act in public!"

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PurpLev

8476 posts in 2282 days


#5 posted 1082 days ago

you could use a large hole saw, or use a bandsaw with a circle cutting jig (if you have a clean blade you shouldn’t have to sand the template, although you could smooth it out if you choose to). both will result in a center hole which the router template solution will not have so might be more fitting.

the lathe idea is also great if you have one.

-- ㊍ When in doubt - There is no doubt - Go the safer route.

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Mean_Dean

1386 posts in 1781 days


#6 posted 1082 days ago

Gerry, I don’t have a lathe. I’m thinking about a hole-saw but it will leave a rough edge, which will require sanding, thus making it not perfectly round….

-- Dean

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Blakep

232 posts in 1436 days


#7 posted 1082 days ago

Find you something that is the size that you want and use turning tape to stick it to a block of wood and use your router with a flush cut bit and let the bearing follow the round object that you are using.

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willie

464 posts in 1088 days


#8 posted 1082 days ago

You’ll need to find something to use as a template. Cut blanks close to finish size. Attach to template and trim with flush trim bit on a router table.

-- Every day above ground is a good day!!!

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Mean_Dean

1386 posts in 1781 days


#9 posted 1082 days ago

Ok, sounds like I need to find a perfectly round object to use as a template, rather than creating one myself.

But if I could make a template myself, I could make it the exact size I want for my coasters.

There has got to be a way to make a template!!

-- Dean

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TheDane

3741 posts in 2297 days


#10 posted 1082 days ago

Is a hockey puck (3” in diameter) big enough?

—Gerry

-- Gerry -- "I don't plan to ever really grow up ... I'm just going to learn how to act in public!"

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TheDane

3741 posts in 2297 days


#11 posted 1082 days ago

If you have a flush trim bit with a replaceable bearing, you could install a bigger bearing and use a hockey puck to get a larger diameter. They are perfectly round, and at one inch thick, might make a decent template.

—Gerry

-- Gerry -- "I don't plan to ever really grow up ... I'm just going to learn how to act in public!"

View richgreer's profile

richgreer

4522 posts in 1708 days


#12 posted 1082 days ago

Another option for making a coaster is a hole saw.

A suggestion regarding coasters – - Drill a shallow flat hole in the bottom of the coaster and insert a magnet. Glue the magnet in place. (Epoxy or thick CA glue).

Why? – The coasters will stack very nicely.

I use a 3/4” forstner bit and an 18 mm by 3 mm rare earth magnet, but you could get by with a smaller magnet.

-- Rich, Cedar Rapids, IA - I'm a woodworker. I don't create beauty, I reveal it.

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Blakep

232 posts in 1436 days


#13 posted 1082 days ago

I think the only way to make the template and having it perfectly round without sanding is going to be a lathe. You could draw a perfect circle and cut it out with a bandsaw and then get after in with a block with sandpaper and a caliber but good luck with that. The hockey puck or anything perfectly round to use as a template would be the way that I would do it. Just write template on the first one you make and then you can say you made the template haha

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PurpLev

8476 posts in 2282 days


#14 posted 1082 days ago

if you were around me you could stop by and we could turn a template for you. maybe there are turners around you that wouldn’t mind helping out?

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View higtron's profile

higtron

192 posts in 1311 days


#15 posted 1082 days ago

I cut my discs for my drum sander on my cross cut sled on my table saw, from the edge of the sled measure over to your radius point drill a small hole I used a 1/4” and a 14” dowel for the pivot point drilled a shallow hole centered in your blank just keep cutting facettes off the square blank until it’s almost perfectly round your last move is to spin the disc through the blade slowly, and you’ll have a real nice circle and supriseingly smooth it’s fast too. This is a technique I got from Jim Toplin’s Tablesaw Magic only he made a special fixture that rode in his miter slot in my case I already have one it;s my crosscut sled.

-- If I cut it too short I can scab a piece on, but if it's too long what do I do?

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