Routing question

[goofy]

I don't have much experience (yet) with a router, but I'm learning along the way.

Can you cut a circle with a router? and secondly, if I have a circle cut (2 1/2" diameter), how can I enlarge that hole with a router? Please provide detailed explanation if possible.

The purpose is for cutting out a hole for the trackball to go into. The best I could get access to was a 2 1/2" hole saw. So, I cut a 2 1/2" hole in my wood and want to mount my 3" trackball into that hole. I'd like it as high as possible, but it looks like I could only get it to about .68" above the top of the wood if I chamfer the edge as much as possible (still figuring exactly how to do that too).

But, if I could use the router to enlarge the hole or create a new one, that would be great.

Anyway, I'm looking to learn as much as possible and what funner way than to built arcade controls. So, any help, suggestions, lessons, etc. are very appreciated.

p.s. my other problem is I only have access to a drill press once a week, so if I can avoid having to use that, I can do things quicker.

Thanks.

--goofy

[javeryh]

To cut a circle you can make a router fence with an adjustable pin on the end.  Adjust the pin so the distance between it and the edge of your router bit is the radius of your circle.  Drill a hole in the center of your circle to hold the pin and begin cutting.  The pin is the center point and stays fixed and the router moves around the circle.  This is probably only good for larger circles though.  2-1/2 inches is kind of tight and they make forstner bits that size anyway which would be much easier...  

[DrewKaree]

Can you cut a circle with a router? and secondly, if I have a circle cut (2 1/2" diameter), how can I enlarge that hole with a router? Please provide detailed explanation if possible.

Yes you can cut a circle with a router.  You can make a template with some MDF, make a circle as large as the hole you want, plus the distance from the outer edge of your router base to the edge of the bit.  Take that piece and put it over the area you want to enlarge.  Use a pattern bit and run the router around the inside of your template.

if I chamfer the edge as much as possible (still figuring exactly how to do that too).

Get a chamfer bit for your router - specifically, the bit that has a bearing on it so you can run the bearing around the hole sides

[versapak]

Yes you can cut a circle with a router.  You can make a template with some MDF, make a circle as large as the hole you want, plus the distance from the outer edge of your router base to the edge of the bit.  Take that piece and put it over the area you want to enlarge.  Use a pattern bit and run the router around the inside of your template.

Isn't the problem cutting the circle in the first place though? If you can cut a circle template, then I imagine you could cut the circle in the project wood as well.

I am no expert by any means, so I can't really give much of an informed answer here, but I would think that a jig saw would be the way to go.

[Wizard of DelRay]

goofy:  Just curious as to why you are cutting a circle for only the trackball.  Wouldn't it be easier to just attach it to a mounting plate and recess the plate?

[DrewKaree]

Isn't the problem cutting the circle in the first place though? If you can cut a circle template, then I imagine you could cut the circle in the project wood as well.

depends...if the hole is small, he'd have a hard time.  

There actually is a better way to do it, but it's one of those things that I can't explain....I'd have to show him.  At that kind of stuff, I have a hard time 'splaining it, otherwise I wouldn't have to show him

But yes, you are correct.

I'm not sure his router has the capability, but I'll see if I can find pictures of what he needs to use

[goofy]

I want to mount the trackball higher than with a mounting plate like this guy did (http://www.willcoxonline.com/mame/controlpanel/controlpanel.htm)

[DrewKaree]

OK, got it, but given time to think about it, this won't work either.

These are the things I'm talking about


I call them "collars", and I know that isn't what they are....now I know they are called router bushings.

You'll need a hole saw and a drill.  You said you use a drill press when available, so that'll prolly be best solution for you.  Jigsaw could work, but you won't have the same smooth rounded edges you got with the saw.
Same reason making a template would be silly, now that I look at it....if you could make that nice smooth hole, you wouldn't need the template.  

Get the hole saw and use the drill press.  Any other way you'll prolly just piss yourself off that you didn't do it that way.

[javeryh]

Use a forstner bit for the most accuracy.  Check out http://www.mlcswoodworking.com/shopsite_sc/store/html/smarthtml/pages/forsbit.htm for some good ones - free shipping too!

[Wizard of DelRay]

I want to mount the trackball higher than with a mounting plate like this guy did (http://www.willcoxonline.com/mame/controlpanel/controlpanel.htm)

Gotcha.  Good luck with your CP.