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Not sure how to cut a chamfer. HELP !!!

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Forum topic by johnhutchinson posted 62 days ago 943 views 0 times favorited 37 replies Add to Favorites Watch
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johnhutchinson

505 posts in 227 days


62 days ago

Topic tags/keywords: chamfer jig shaping

I have a round disk that’s 1” thick x 5-3/4” diameter, and I need to cut a 60-degree x 1/2” high chamfer around the perimeter. I can think of two DANGEROUS ways of doing it, but I’m looking for a non-911 solution.

I don’t care if there’s a center hole because I’ll plug it.

I also need to drill 36 equally-spaced holes, centered on the face of the chamfer, but I know how to safely and accurately jig that.

-- John - Central Ohio - "too much is never enough"


37 replies so far

View Marcus's profile

Marcus

1041 posts in 617 days


#1 posted 62 days ago

I would head to the bandsaw for this…tilt the fence, hole in the middle of the piece to pivot around (just like cutting a circle).

If you dont want a hole showing, just plug it with a dowel. Better safe and have a dowel showing than cut off a finger.

View JAAune's profile

JAAune

753 posts in 914 days


#2 posted 62 days ago

You didn’t mention if you had a lathe or not because that’s precisely the sort of work a lathe does well.

Outside of that I’d consider a radius jig that can be presented to a stationary sander at an angle.

-- See my work at http://remmertstudios.com and http://altaredesign.com

View Greg The Cajun Box Sculptor's profile

Greg The Cajun Box Sculptor

4932 posts in 1906 days


#3 posted 62 days ago

I have done something very similar before with a 45 degree chamfer. I used a chamfer bit on a router table and used a starting pin to do it freehand.
Use an Incra Protractor to lay out the markings for the holes (every 10 degrees for 36 holes) and drill them prior to doing the chamfer

-- Every step of each project is considered my masterpiece because I want the finished product to reflect the quality of my work.

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firefighterontheside

3250 posts in 454 days


#4 posted 62 days ago

I think you’d be safe with the router. Either with a hand held router with the piece sort of anchored so it won’t move. You may want to make a few passes. Other way is on the table freehand. I do this frequently when making quilt stands. The pieces are oddly shaped, but I need to round over all the edges. Use something to pivot the piece into the bit then maneuver it all the way around. Again you may need to make several passes. I understand though that when something feels unsafe, it may make it unsafe. Be sure that you are not making a climb cut, that would be unsafe and could pull your hands into the bit. Take care.

-- Bill M. I love my job as a firefighter, but nothing gives me the satisfaction of running my hand over a project that I have built and just finished sanding.

View Iwud4u's profile

Iwud4u

270 posts in 126 days


#5 posted 62 days ago

I would make a jig for my table saw something like this. I would start at the corner and make several passes moving the fence in a little each time until I reached the desired depth. I would place the circle into the guide and raise the blade into it while turning the circle backwards to let the blade cut into the material.

DISCLAIMER:
The drawing is for the conceptual idea only, you should improvise the idea to make it work safely for you.

-- It's far better to be criticized by a wise person than applauded by a fool --

View Craftsman on the lake's profile

Craftsman on the lake

2364 posts in 2035 days


#6 posted 62 days ago

Okay, here’s an odd idea. Mount the disk with a bolt and nut in the center hole. Put it in a drill press. Glue some 60 grit sandpaper on an angle block and clamp it to the table. Bear down on the drill press handle till the correct depth chamfer is reached.

-- The smell of wood, coffee in the cup, the wife let's me do my thing, the lake is peaceful.

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mrjinx007

1315 posts in 365 days


#7 posted 62 days ago

+ JAAune

-- earthartandfoods.com

View splinter1000's profile

splinter1000

3 posts in 80 days


#8 posted 62 days ago

I would use a 12 inch disk sander with mitergauge slot perpendicularly arranged to the surface of the disk (Delta has a combination disk / belt sander with this capability but you can easily use a temporary table with the aforementioned slot clamped on to the table of a benchtop 12 inch disc sander). A small moving block that includes a small pin pricking the center of the workpiece is moved in the miter gauge slot toward the spinning disk to produce the chamfer ( i.e., the table is obviously tilted). A stop block can be affixed in the miter gauge slot to ensure that the desired diameter is maintained. A preliminary planing to remove most of the material will reduce the sanding required. See the following:

http://2.bp.blogspot.com/-twl_q2F472M/T2Lc5tTJzwI/AAAAAAAABHI/jqwcgH8rhuQ/s400/Sanding+Jig+for+Circles1.jpg

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Arlin Eastman

1852 posts in 1158 days


#9 posted 62 days ago

Wood Lathe

Arlin

-- It is always the right time, to do the right thing.

View Fettler's profile

Fettler

109 posts in 594 days


#10 posted 62 days ago

Like you inferred that’s extremely dangerous to do on a table saw. The blade’s forward momentum is going to try to chuck the work piece at you. Any lateral movement can cause the blade to bind.

You could do this with safely with a hand router w/ a guide bearing, pinned piece + table router, a jig for a bandsaw, a lathe or possibly a custom shooting board.

-- --Rob, Seattle, WA

View Bill White's profile

Bill White

3342 posts in 2558 days


#11 posted 62 days ago

Router table if ya have one.
Bill

-- bill@magraphics.us

View TerryDowning's profile

TerryDowning

996 posts in 715 days


#12 posted 62 days ago

Wow, this discussion really highlights the creativity, and versatility of wood workers.

Rarely is there one and only one way to perform an operation.

So much depends on available tools/machining capability.

Great ideas and suggestions.

Good to see that the OP is asking a question to keep himself safe.

I Really like this site for this reason. (among others) Great Job everyone.

-- - Terry

View stefang's profile

stefang

12563 posts in 1931 days


#13 posted 61 days ago

A lathe would be the easiest and safest tool for this job and if the lathe has an indexing system the holes could be marked with that and if the holes are 90deg. to the bottom they could also be drilled while still mounted on the lathe using a Jacobs chuck to hold the bit.

-- Mike, an American living in Norway.

View bigblockyeti's profile

bigblockyeti

1373 posts in 318 days


#14 posted 61 days ago

I would be inclined to make a jig for the bandsaw where you would first tilt the table to 45 degrees and have the jig designed to add 15 more degrees for the total 60 required. While it would leave a rough finish, you could use the same jig on a disc sander, again, tilted to 45 degrees and finish the surface to the final dimension. You could then tilt the drill press table 15 degrees the other way to register the 36 holes that need to be bored perpendicular to the chamfer face. Getting all 36 holes evenly spaced could be done after cutting and sanding, with a protractor, sharp pencil and patience while laying out. A brad point bit would help keep the holes dead on your mark.

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Steve Kreins

314 posts in 228 days


#15 posted 61 days ago

WHY HASN’T ANYONE ASKED WHY HE’S BUILDING A SPACE SHIP? I THINK THIS IS A PROTOTYPE FOR SOMETHING BIGGER.

-- I thank God for everything, especially all of you!

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