Hi All.

 

I was trying to install a home-made resonator in a cigar box, but was unable to successfully cut a round hole in the box for the resonator. So, I thought I'd open this topic up as an area of discussion. I know there are a variety of techniques from using routers with a circle cutting jig and hole cutting attachments for rotary cutting tools (like Dremel tools), to drill attachments (both fixed diameter and adjustable diameter attachments (up to 200mm or 4.75")).You may know of other ways to cut these circular holes, so please add to our discussion by describing your method.

 

What I Tried:

As I have no router or rotary cutting tools, and the options for drills wouldn't give me the 5.75" diameter hole I needed, I decided to devise a home-made hole cutter using a small board, a screw and nut, and a carving chisel with a side facing blade. Here is a diagram of what I was thinking:

 

And when I tried it, it seemed like it might work okay, but as the circle cutting progressed, I broke the small board holding the knife, so I decided to do it free hand and started making sloppy mistakes, and then the hole cut through the sound board, I got rushed and broke the rest of the hole thru, splintering the sound board pretty badly. Not liking my sloppy work, I decided to remove the sound board and replace it with 2mm plywood veneer. And, I decided to hold off a while longer at building a Reso-CBG until I got better cutting holes. I did take a couple photos before things started going wrong. Here are those 2 photos:

And:

Again, this technique could have worked if my "rotating beam" was a thicker/stronger piece of wood. What I used was a scrap of 2mm plywood veneer, and that proved not strong enough. Notice that you have to cut around and around the circle several times with a fair amount of force to cut through the sound board. When it finally breaks through, the wood will likely splinter. To prevent this you should place some scrap wood between the soundboard and your work surface. If you are working on a separate sound board that you will glue to your box latter on, this extra support won't be needed as your soundboard will be resting directly on your work surface. You also should take your time and be very patient. It's too easy to want to rush through the job and mess it up.

 

Well, that's all I have for now.

 

-Rand.

 

http://ultimate-guitar-building.com/site-map/

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Replies to This Discussion

Do you have a Dremel Tool?  I'm pretty sure Dremel makes a hold cutting jig that is reasonably affordable, i.e. less than $20.

Hi Dave,

No, I don't have a Dremel or other rotary cutting tool. I've seen them in the stores, but like routers, the million and one attachments that you can get for them has caused me to shy away from them. If I had a basic understanding of what tool bits and the like I need for CBG making and how to use them, maybe I'd go for it. There should be a discussion group about using dremel tools and maybe another for routers to discuss how these tools are basically used. I know, everyone else has access to Youtube, where there are probably dozen of these how-to videos, but I live in China where Youtube is blocked and I didn't have the foresight when I was last in the States. I will look into the Dremel and Router options. What information I find, I'll put here.

-Rand.

 

 

 


The  Dremel 678-01 Circle Cutter and Straight Edge Guide makes circles from 3/4-in to 12-in. Precision stamped steel construction for accuracy and durability. Attaches quickly and easily without tools. Depth adjustment allows easy setting of the correct cutting depth. Straight Edge Guide allows routing or cutting in a straight line. Can buy online at Amazon.com for about $12.

I'm still not sure if this attachment works on all Dremel tools, or just one or two specific models. Also, I am not sure which cutting bit would work the best. Would this attachment work on third party rotary cutting tools? Any ideas? What have you used successfully?

I did see a few other interesting Dremel tool attachments:


I just wonder, as router tools, whether these tools are strong enough to cut more than soft pine wood? Perhaps a real router would be better. What do you think?
Looks likes I'll need to start saving for one of the Dremel rotary cutting tools and at least a couple of these attachments.
-Rand.
I use mine a lot !!   ,,It an older model ,, takes some practice to get aclimated to it ,,, key i find is to let the speed of the dremel do the work .. don t force it .. i have drilled, cut up to 3/4 inch stuff with no problem s... I am steady buying attachments for it ..

HI Richard.

Thanks for your input about using Dremel tools. Do you know if it takes a different kind of "drill bit" in the Dremel tool to cut a circle. I really have no experience with Dremel tools, but somehow I think it might require a different cutting tool/bit to essentially "cut like a saw". As I said before, with all the attachments, drill bits, cutting wheels, grinder wheels and other tool options, it's kind of an intimidating tool to take on as a novice wood worker. I would like to learn more, though. Could turn out to be the ideal tool for a 101 little jobs around here.

-Rand.

 

Rand,

Like you, I live overseas, so that can make "obvious" or "basic" tools hard to come by. Time consuming, at least.

I do have some experience with the Dremel tool systems. Last year, I used my Dremel to carve a 3-ft high boar's head from Styrofoam blocks; unfortunately, I used it so continuously, I burned up the motor. So I bought another one ( they are available here locally in KSA in a couple of homeward stores). Anyway, I have the drill press workstation, and the router table attachment, as well as the workbench multi-vise, and the circle cutting attachment. The bits used for circle cutting are very similar to those developed for the Rotozip tool, which I also have, use extensively for theater set and props construction projects, and absolutely swear by. The Rotozip, BTW, is basically a scaled up Dremel tool with a more powerful motor and heavier bits / attachments. It is great ( and much better than a standard reciprocating jig saw) for cutting straight lines, freehand curves, starting vertical holes in tight corners, etc. The Dremel works the same way, but is a better scale for Pinewood Derby cars ( which is why I first bought one after getting frustrated using basic hand and power tools - once you get used to it, you can be very precise with it), and, incidentally, CBG construction. I would also encourage you to just go ahead and get the 160 - 180 extra parts clamshell accessory kit, which has loads of extra grinding wheels, sanding wheels and discs cutoff wheels, and even extra drill and cutting bits used for things like...circle cuts. Don't be intimidated by the variety of tools and attachments; the Dremel site does a nice job of briefly explaining what sorts of uses these can be put to. I note that you are in Shenzhen, Guangdong; while my Dremel was assembled in Mexico, I'd bet the workshops in Changzhou have a very similar type tool / toolkit. Might be worth checking into?

Just for grins, I did a quick Google search on "Dremel rotary tools China," and found Changzhou Wujin Dacheng Industries and Trading, that sells LOTS of Dremel-type rotary tools and kits...aaaaand...Shenzhen Baoan District Xuting Molding , Hardware Firm, that sells single tools / kits for $45 - 90.

Oily
Rand,

Further to my last, check this out:

http://zgxuting.en.alibaba.com/product/425877490-212123825/Rotary_e...

Right there in Shenzhen, Guangdong, works on both 110 / 220 V, and sells for about $50!

Oily

Hi Oilyfool

Thanks for the research. Now I'm feeling the pressure to buy. But 320 RMB ($50 US) is not a bad price. I wonder if these Dremel tool clones work with the Dremel attachments I mentioned above? Well, if not, I could always build a jig of my own, just beefier than the last one. The 110/220V power supply is definitely a plus. Thanks again.

-Rand.

 

Rand,

My pleasure. A lot of them do work with many standard Dremel attachments, according to the few woodworking forums I looked at.

Good luck. With your purchase ;-),

Oily
Yes it does ,, they hav e two models ,,,  one u can start drill ur hole urself ,, second have tohave a pilot hole ,,, both work ,, I like the second one better for holes  or detail cutting ,, use the other one ,, got the router adapter ,, it lets u set the depth ,, when using a nut  ,,cut a real clean slot with it         They are magic little things ,, all the stuff is quite inexpensive ,, what we use em for ,, really don t need any real "heavy" power tools don t remember what i paid for the bit ,, but thinking less than 2 bucks .   just my thoughts  but 101 woodwrking projects and as u get more detailed ,, u be suprised how much u use it ...  try to get the kit with the one that has the extension cord ,, u hold it just like a pencil to work with ,,, u can even carve with it once ur hand get steady  ..amazing tool 

Rand Moore said:

HI Richard.

Thanks for your input about using Dremel tools. Do you know if it takes a different kind of "drill bit" in the Dremel tool to cut a circle. I really have no experience with Dremel tools, but somehow I think it might require a different cutting tool/bit to essentially "cut like a saw". As I said before, with all the attachments, drill bits, cutting wheels, grinder wheels and other tool options, it's kind of an intimidating tool to take on as a novice wood worker. I would like to learn more, though. Could turn out to be the ideal tool for a 101 little jobs around here.

-Rand.

 

Hi Richard,

When you say "they have two models", are you referring to dremel tools or hole cutter attachments?  I'm not sure from what you have written. It's probably clear to everyone else who reads this, but I'm a bit slow and everything has to be clearly stated. And by "extension cord" you are referring to that long cable-like attachment do-ma-jiggy that fits between the rotary tool's bit "chuck" and the actually cutting bit. I saw a picture of one, and they do look pretty handy. I don't think many of the Dremel clone machines have those. I guess I need to shop around. Thanks for your input, Richard.

-Rand.

Rand,

 

I think Richard is referring to the flexible shaft attachment when he says "extension cord." And yes, the non-Dremel rotary tools available in China can be fitted with one:

 

 http://stekolindustry.en.made-in-china.com/product/eqOnQWdGhPkA/Chi...

 

They are really useful for detail carving, allowing you to just use the carving tip very close to your fingers, without supporting the weight of the rotary tool motor in your hands (if you have the drill press / workstation or other supporting device).

 

"Somebody's goin' on a tool buyin' spree; somebody's goin' on a tool buyin' spree..."

 

Did I mention that in college, I was known as The Professional Bad Influence? >:-E

 

Oily

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