boycabrera - Oval & Circle Cutting Router Jig

UPDATE: 

• Type 1 Arm Connector (connects arms to main jig body) has been updated to fit better

• I have added both the NEW and ORIGINAL styles of Mounts. 

• The ORIGINAL uses more filament, but has the potential for expansion.

• The NEW uses far less filament, can be adjusted easily, avoids getting snagged on the BASE, and eliminates the need for tons of small additional pieces. 

About this Ellipse/Oval Jig for Routers:

I was struggling to find a decent router jig for making large ovals (the sort of size suitable for a coffee table). The ones I could find, were beyond expensive, lacked any way for size expansion, were never compatible between multiple brands, and had no easy way to adjust the size of the oval…

So what do we do when the world disappoints us?

Well, we do it ourselves!

So that's what I did. 

Compatibility:

It is compatible with the following major tool brands:

• BOSCH-GKF18V-25N

• BOSCH-GKF125CE

• BOSCH-COLT

• DEWALT-TRIM-ROUTER

• MAKITA

• MILWAUKEE-18V

• RYOBI

• RIDGID

Parts you will need to print:

BASE:

• Print either the BASIC BASE or COMPLEX BASE

• Print 2 Dovetail Sliders

• Print 2 M5 Knobs

MOUNTS:

NEW:

• There are 3 types of Mounts in this NEW System

• Type 1 is a Generic Mount that will be sufficient for cutting small or large ovals. Use this to get started.

• Type 2 has a large hole in the bottom, which is meant to fit on top of the Circle Attachment. Use this Mount when a circle is your endgame :)

• Type 3 is similar to Type 1, except that it has a special addition allowing you to secure a Hex/Allen Key to the top. I kept losing track of my Hex Key, so I thought adding this was a smart idea.

ORIGINAL

• Print either the BASIC MOUNT (cannot be expended or do circles) or the EXTENDABLE MOUNT (can be extended, has a mount for a Hex Key, and can also do circles)

• If you print the EXTENDABLE MOUNT you can print the MOUNT EXTENSION ARM, as well as the MOUNT EXTENSION ARM CONNECTORS

• If you want to cut out circles then also print the CIRCLE ATTACHMENT. This piece will work in both the BASIC and the COMPLEX BASE

ROUTER PLATES:

• Find the ROUTER PLATE that works with your Router and Print!

• I have included the STEP Files should you need to make and adjustments (or if you want to customize yours)

SECONDARY ARM PIECES:

• Start by Printing the ARM (200mm)

• You will likely need one for each opening on your selected BASE type (4 for the BASIC & 8 for the COMPLEX)

• To secure the ARM (200mm), you will need to print 1 set of TYPE 1 CONNECTORS and 1 set of TYPE 2 CONNECTORS for each ARM

• Should you still want to increase the permissible size range then you can lengthen the ARM (200mm) by printing the necessary ARM EXTENSION pieces which range from 50mm to 200mm. 

• Print as many as you require and secure them using the ARM EXTENSION CONNECTORS

HARDWARE:

For hardware, I have tried to keep it to a minimum. You will need: 

• 6 - 6mm Stop Collars

• 4 - M6 Linear Bearings

• 2 - M6 Rods (The longer the better to allow for larger Ovals & Circles)

• 2 - M5 x 30 Hex Bolts

• 2 - M5 Hex Nuts

• 1 - M6 Hex Key (to secure the M6 Rods

And that's it!

Usually your Router will come with its own screws to secure it to the Router Plate, so no need to buy those if you don't need to (If you do, they will likely be M4 or M5).

SETUP:

Take the Base (Basic or Complex)

Add the TYPE 1 Arm Connectors

Push in the Arms

Secure with the TYPE 2 Arm Connectors

NOTE: I used this method to reduce the amount of costly hardware required

Get your Dovetail Sliders and insert the two M5 x 30mm Hex Bolts

Before we go on, let's set up the Mounts by adding two M6 Linear Bearings

Take the TOP of the Mount and use a clamp to press it on tightly. Push in the 2 Stop Collars 

Push the two M6 Rods through each hole

Secure the Rods using a Hex Key

NOTE: You need two of these Mounts, so repeat this setup a second time.

Now that we have our Mounts set up, let's continue!

Add the completed Mount System onto the Dovetail Sliders.

Adjust as desired. 

NOTE: The closer the two Mounts are, the smaller the Oval and the further they are, the bigger the Oval
 

Take your Dovetail Knobs and push in two M5 Hex Nuts

Use the two Knobs to secure the Mounts

Take your chosen Router Plate, add two M6 Stop Collars, and secure the M6 Rods

Now we can see the Final Product!

You are ready to start routing! 

Essentially, you are only limited by the length of your M6 Rods. I use 700mm Rods, but if you want even bigger ovals, then get longer Rods.

EXTRA: Use the included Extension Arms as needed. They couple easily using the Extension Connectors and can be further secured using small screws.

I am looking forward to seeing what y'all make with this!