A Visual History
The Building of Aslan
Cutting a Circle on a Table Saw
Updated 12/12/99
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The plans call for the use of 1/4" plywood as trim pieces for the wheel.  I wanted to use solid red oak.  I don't have a hole saw that is 4 1/2" in diameter, but I remembered this table saw trick.

Start by finding the center of your stock or, alternately, measuring 1/2 the diameter of your finished circle from the blade, and attach the stock to the table saw sled.  The sled should be clamped down to the table saw table.  The blade is lowered until it just barely clears the top of the table saw sled.  The saw is turned on, and the stock is carefully rotated.  Then the blade is raised slightly, and another rotation made.

Here, we're about 1/2 way through the process.  The blade wastes quite a bit of stock outside of your planned circle, but the edges are nice and round.  You'll note some burning of the wood; this happens less with softer wood.

To be safer, you can install a 1 x 2 guard above the blade.  Position it just above your stock and centered over the blade.  That way you won't jam your hand into the spinning blade.

Finished!  After several careful revolutions, a perfectly shaped round disc is made.  The final cut is a little tricky; you can see the triangular pieces that can "fly off."  They don't fly off with any velocity but if you're not thinking, you could try to grab them (you would probably jam your hands into the spinning saw blade that way.) 

As always, be careful.  Use a guard if you can (as described above.)

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