The circle jig sled is awesome. Advantages are, quick set up, repeatability, table saw dust collection. Even the sled was very quick to build. Slap a delrin bar on a piece of plywood to slide on, cut with the plywood with the table saw to establish the edge, using the delrin slide. It's not without risk though. I mentioned above not to rotate the piece on the blade until the material does not extend beyond the other side of the blade. Straight sled cuts until you're ready to rotate, then rotate for finial circle dimension.fender3x wrote: ↑Wed Dec 07, 2022 7:30 pm Well now I am really curious. I have seen that sort of circle jig on the internet, but have never tried it. So far all my circles have been done with a router. Does it have an advantage over using a router?
Also curious how you cut out your baffles. You got rid of most of the excess material, which suggests that you used a router to do the final cutting...but the corners are sharper than you'd expect with a router...
The horn braces needed to be consistent. If they weren't consistent the imperfection would telescope beyond the horn glue up and be visible.
Baffles finish cut was with a jig saw. I wasn't as concerned with that piece since almost all of it is eventually covered up.
I have cut circles with a router but was never a fan. Once the piece is clamped up, rotating the router and power cable around the protruding clamps, and when you get to the last bit to separate the circle the circle lets go and the router always gets into it a little, the dust collection is complicated... pain in the ass