A Light Fitting

I was asked to produce a couple of wood ‘rings’ so a couple of large diameter brass light fitting could remain horizontal even though the location was a sloping beam.  I had a brass fitting, and a piece of cardboard onto which was drawn the roof angle.

Thinking about the best way to do this had a few options, including lathe, bandsaw and drum sander.  But what I decided on was to cut a couple of circles on the router table, glue them together then machine the required angle.

Router Table Circle Jig

This is my router table circle jig – a very simple design for cutting accurate circles.  I use the freehand router table guide (with dust extraction), MagSwitched down onto the cast iron table.

With a piece of pine attached to the nail pivot point, a light groove is routed into the board. The board is then removed, and the excess cut away on the bandsaw.  The board is then returned to the router table to complete the cut.

This is done for all four boards (I’ll get to that in a sec, but yes – all four).

Next, the inside disk is cut away.

Cutting a circular opening

I’m sure there other ways – but this seemed as good as any at the time (and not a jigsaw in sight).

Two of the disks are then glued together (with the grain direction set 90 degrees to the previous to maximise overall strength).  I did this for all four rings, then glued together to create two thick rings.

Glueup was done with all four glued and clamped at once.

Clamping up

I then created a jig to stabilise the ring, at the exact angle required for the fitting.

Angle Jig

It may look quite sophisticated, but all it is, is offcuts from the original ring cuts.  This way I could drop ring after ring into place and they could all be sanded to the same angle.

In this case, I only needed two!

I originally fed this whole unit into the drum sander a few times, but it was taking forever (too fine a grit sandpaper, or something wasn’t just working right), so I moved the jig across to the Torque Workcentre.

Same concept, but this time bringing the tool to the workpiece, not the other way around.

Torque Sanding

This didn’t take long.  Once sanding occurred over the entire ring, the job was finished.  After a quick trip back to the router table with a round-over bit to break the edges, the job was complete.

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