How to make quick 2 1/2 circles

Woodshop
#1

I want to make some 2 1/2 inch circles out of a 2x4. I have a keyhole saw but it uses a drill bit in the center, I don’t want a hole in the middle of my circles. What is the easy way to do this?

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#2

Well, how close to 2.5 inches are you looking for, versus the 2 inch depth? They make bimetal hole saws with nothing in the middle.if you need a bunch of 2.5 inch pucks, I’d recommend turning on the lathe, and then slicing pucks.

7 Likes
#3

I agree with Doug. It would be easier to use a 4x4 to turn them I think. Or you could glue two together along the faces.

1 Like
#4

How thick?

2.5" x .250" https://woodcrafter.com/plywood-circles/?sku=pc2.518&network=g&device=c&keyword=&campaign=6463587305&adgroup=pla-295732838093&gclid=EAIaIQobChMI04e7m4Tx5wIVip-zCh3I3gtcEAQYAyABEgKPPPD_BwE

2.5" x .125" https://www.walmart.com/ip/WOODNSHOP-25pcs-2-5-wide-X-1-8-inch-WOODEN-CIRCLES-PLAIN-UNFINISHED-WOOD-CRAFT-FOR-DISKS-TAGS-EARRINGS-WEDDING-PLAQUE-JEWELRY-DI/872890934

2.5" x .59" https://www.etsy.com/listing/713016189/2-circle-wood-cutout-25-unfinished?gpla=1&gao=1&&utm_source=google&utm_medium=cpc&utm_campaign=shopping_us_d-craft_supplies_and_tools-blanks-forms_and_shapes-other&utm_custom1=09a47ddc-6c53-464d-8c23-e791a73d0a58&utm_content=go_1843970773_72423993031_346362959472_pla-322226746264_c__713016189&utm_custom2=1843970773&gclid=EAIaIQobChMI3NHUk4Xx5wIVjZ6zCh25EAgpEAQYBSABEgIbmPD_BwE

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#5

You can cut a 2.5" circle in 1/4" ply on the laser. Hot glue/double sided tape to the 2x4". Rough cut it in the bandsaw. Trim to exact shape with a flush router bit, or more laboriously, sand to finish shape on the belt sanders.

3 Likes
#6

2.5 inch hole saw without the Drill bit guide used in a drill press to keep the Saw from wandering…

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#7

Cut the circle from the 2x4 using the piloted hole saw you mention above. Cut 2.5" circles in ply on the laser. Glue the laser cut circles onto the 2x4 circles to cover the holes.

You can also cut perfect circles on a bandsaw with a little jig, but I don’t know if our band saws can cut a circle with that tight of a radius.

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#8

Some hole saws don’t have the center pilot bit. I have a Milwaukee set and the center drill bit is removable. I don’t have the 2.5 size though, sorry.

But depending on the thickness of the ply, laser might be your best bet.

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#9

Using them as a base for resin dragon eggs, so about 1.5" thick. Thanks for the links though.

Nathan

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#10

How important are the aesthetics of the piece? You could consider plugging the hole that a hole saw’s pilot bit would make with a dowel.

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#11

These might be a bit larger in diameter than you want, but I’ve used these as easy craft stands for various projects in the past.

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#12

What would you use to slice the pucks? How would you secure the turned cylinder so it doesn’t roll around when slicing the pucks? I’d like to try this.

#13

Perhaps a parting tool?

2 Likes
#14

Or band saw with appropriate sled. Or table saw with crosscut sled. A lot of ways to skin that cat slice that puck.

3 Likes
#15

I make wooden circles all the time. 2.5 - 4 inches. First I use a band saw to get a close shape and then use the sanders to get the final shape. 10-20min for a set. Each set has to be a custom size so this works for me. Not sure if this would work for you. Just a suggestion.

1 Like
#16

How many do you need? That would make a lot of difference in the approach. E.g.: turning glued up 2x4’s or using a 4x4 and turning down then band sawing pucks may be faster.

Easiest, IMO:

#17

I would say CNC could make you circles for days, how many do you need?

1 Like
#18

I only need about 10 total. I think the idea of doing a 4 x 4 in LA that’s the best solution, thank you everyone for your time on this

3 Likes
#19

Use the hole saw and veneer the flats to cover the hole.

#20

Sled for sure was my thought