I'm planning to cut some circles and ovals in 1/4" (6mm) plywood. My goal is to have the cut-out shapes left intact, starting from 4" (10cm) in size. I've seen various methods online using routers and jigs, but I'm curious if they're as straightforward as they seem. Ideally, I'd prefer to use my jigsaw, but I'm wondering about the challenges of achieving a perfect oval cut. What blade do you recommend for this? Is there a jig that works well with a jigsaw? I'm not a woodworking expert, but I'm familiar with tools. What's the minimum equipment I would need for cutting through wood, and how easy is it really to cut these shapes?
3 Answers
If you stick with the jigsaw, opt for the thinnest blade. Make sure to avoid swaying the jigsaw side to side while cutting; just keep it steady and smoothly rotate as you go around the curve. Since I often make props, I just cut as closely as I can, leaving about 1/8" around my line, then sand it down for a smooth finish. Just take it slow for the best results!
Using a router generally allows for greater accuracy, especially if your jig is well-made. A jigsaw can make less clean and precise cuts because the blade might bend during the process. If you’re going with a router, the circle jig is pretty simple to use. However, if you’re aiming for an oval, it can get a bit trickier. But keep in mind that for smaller circles, relief cuts can really help with the jigsaw!
If you plan on doing this a lot, I definitely recommend making a template for your circles and ovals. That way, you won’t have to set up your jig repeatedly. Use the router with a bearing-guided bit that traces along the edge of your template—it can save so much time and effort. Plus, making templates is particularly great for small shapes!
Totally agree, a router really does provide a cleaner cut overall. And yeah, while the circle jig is easy, the oval jig definitely requires a bit more setup and math.