How To Cut a Perfect Circle With a Router

Cutting a perfect circle is challenging for beginners and experts alike—but it’s not impossible. While it might be tempting to reach for a jigsaw, using a router with a simple circle jig can give you cleaner, more consistent cuts. This technique is ideal for creating tabletops, wall hangings, custom cutting boards, and any number of other woodworking projects. 

In this article and the video above, Jenn Largesse shows us how to use a Ryobi router to make a circle jig, sharing expert techniques and tips along the way.

*Costs in this article represent an average of prices we sourced from Home Depot and Amazon.

Why Cut With a Router?

A router is a versatile tool that many homeowners overlook. While many woodworkers use it to add decorative edges to furniture, that’s hardly its only function. If you need to cut a perfect circle, the router’s ability to make clean, precise cuts makes it the best choice for your project.

In the video above, Largesse uses a RYOBI ONE+ cordless trim router, but any quality trim router will be fine.

Required Tools and Materials

Making your own Ryobi router circle jig is a relatively simple project, but there are still a few things you have to do before you begin.

Materials

Here are the materials you’ll need:

• ¼-inch board
• Craft wood
• Nail

Tools

Have the following tools on hand:

• Clamps
• Countersink bit
• Drill/driver
• Measuring tape
• Spade bit
• Trim router

Safety Precautions

Always use proper safety precautions when working with power tools. This includes wearing protective eyewear and using caution when operating power tools.

When in doubt, follow the Occupational Safety and Health Administration (OSHA) Guide for Protecting Workers From Woodworking Hazards.

Creating a Custom Router Circle Jig

Before cutting your circle, you’ll need to create a simple circle jig that attaches to your router. This jig will serve as a template for your cut, so it’s important to take your time and get it right.

Follow these steps below to make a circle jig:

1. Remove the base plate from your router using a drill or screwdriver.
2. Trace the base plate onto the ¼-inch board, marking the screw holes and bit opening.
3. Drill out the marked screw holes using a countersink bit to ensure the screws will sit flush.
4. Use a spade bit to create the center hole for the router bit.
5. Measure and mark the desired radius of your circle on the jig. This will be your guide for cutting the circle.
6. Drill a small hole at the radius mark for the pivot point, which will help maintain a smooth circular motion.
7. Once you have your radius, ensure your workpiece is large enough for your desired circle.
8. Secure the workpiece to your work surface using clamps or screws to prevent any movement.
9. Find the center of your workpiece by drawing diagonal lines from corner to corner. Mark this center point clearly.
10. Attach the custom jig to your router, replacing the original base plate.
11. Place a small nail through the pivot point hole in your jig.

Cut the Perfect Circle With Your Ryobi Router Circle Jig

Now that you have your own custom circle jig, you’re ready to start cutting your circle.

Here’s how:

1. Place the router with the jig onto the board. Line the nail from the pivot point up with the center of the board and hammer it into the board. Do not tighten it too much, as you will need to move the router around easily.
2. Set the router bit just slightly past the depth of the jig. This will serve as a shallow initial cut.
3. Turn the router on and start cutting the board. Turn the jig at the pivot point as you cut to create a circle.
4. After the first pass, lower the router bit again and make a second pass.
5. Repeat this process, gradually lowering the bit with each pass until you’ve cut through the workpiece.

Tips for Success

For best results when cutting circles with your router circle jig, keep the following tips in mind:

• Clear sawdust regularly: This helps maintain visibility and prevents the router from overheating.
• Keep the router level: Maintain consistent pressure to get an even cut depth throughout the circle.
• Take your time: Multiple shallow passes produce cleaner results than cutting through in one go.

Resources

Jenn Largesse demonstrated how to cut a perfect circle using a RYOBI ONE+ cordless trim router by Ryobi Tools.

Largesse is the editor of multiple DIY blogs, including House One and Build Basic.

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