Cutting a circle in solid material

[HowardH]

I am going to build another Big Green Egg cart except this time I plan on using a solid surface or tile for the top.  I will need to cut a 21" diameter circle for the egg to fit into.  Is there a bit I can get for my OF1400 that I can use?  Any other suggestions?  Short of buying a MFS, I don't know how to use this router to cut a circle, either.  

 

[tbellemare]

Howard:

Do you have a good (Festool) jigsaw?

Tom

 

[HowardH]

Tom, I have the next best thing - a Bosch.  This may be one of those things where it is worth it to take the material to a professional fabrication shop.

 

[BMH]

Howard,

I just finish making some large round mirrors wood frame using the MFS and a Festool spiral bit. A real pleasure with beautiful results. I have been using the MFS on multiple projects since then. Let me help you with the right decision.

1-It's Xmas
2- Big Green Egg owners only go for the best
3-When you have people over for a Barbecue they are going to judge you by how well that Green Egg cart is built.
4-Every time you Barbecue that perfect circle is going to make you happy.

Bruce

 

[Chuck Kiser]

I am going to build another Big Green Egg cart except this time I plan on using a solid surface or tile for the top.  I will need to cut a 21" diameter circle for the egg to fit into.  Is there a bit I can get for my OF1400 that I can use?  Any other suggestions?  Short of buying a MFS, I don't know how to use this router to cut a circle, either.  

Howard,

Get a solid carbide up-cut spiral bit for your OF 1400. Then make yourself a 'teardrop' base for your router. The size of the teardrop will depend on the radius you desire. The base can be very simple 1/4" ply would work fine. Determine your distance from outside edge of router bit to center of desired circle. Drill centering hole in 'teardrop' template. Place fixture on material, drill thru centering hole into material, insert holding pin and route away.

HTH

 

[DustyLeigh]

I have a Big Green Egg and built a table for it. Your last step in building the table is probably going to be cutting the hole, so you need support for the router. Attach a 2x4 underneath the top from front to back to support the router. You can remove this 2x4 after the cut. I didn't own my router when I built mine and I used a jig saw. The router will do a nicer and easier job.

 

[HowardH]

Howard,

Get a solid carbide up-cut spiral bit for your OF 1400. Then make yourself a 'teardrop' base for your router. The size of the teardrop will depend on the radius you desire. The base can be very simple 1/4" ply would work fine. Determine your distance from outside edge of router bit to center of desired circle. Drill centering hole in 'teardrop' template. Place fixture on material, drill thru centering hole into material, insert holding pin and route away.

HTH

Would this method work in something like Silestone?  I am concerned about excessive heat building up.  Would I have to spray the stone with water while I am cutting it?  What about granite? I don't have a solid carbide UC spiral but a HSS instead.  I would imagine any solid surface product would quickly ruin this bit.  I like the idea about the oversized teardrop base. 

 

[Brice Burrell]

.....I like the idea about the oversized teardrop base. 

I know you thinking about the home made base (I like this idea too) but I just thought you'd like to know there is a MFS for sale in the classified section right now.

 

[jeffinsgf]

Before you make any decision about how you're going to cut the hole, you need to decide what material you're going to use.  Corian? or something like that can be machined with your router.  Granite is an entirely different matter altogether.  If you use man-made solid surface counter material, you can make your own trammel point jig as has been mentioned.  If you go with granite, I would have the supplier cut the hole.

I'm another BGE Egghead.  I have a medium and a large.

 

[HowardH]

LOOOOOOOOVE my egg!!!  [big grin] [big grin] [big grin] [big grin] [big grin] [big grin] [big grin] [big grin]  Got rid of the gas grill.  Never looked back.