For this build, I show how to build an oval cutting jig for your router.
Click Here To Download A Set Of Plans to Build This Router Jig
Affiliate links for some of the products I used in this build.
° 1/4″ 20 bolt https://amzn.to/2PjOxc9
° Star Knob https://amzn.to/2EgCqvo
° 1/4″ Washer https://amzn.to/2SypILO
° CA GLue https://amzn.to/2UgxNX4
° CA Glue activator https://amzn.to/2KVWdki
If you need to cut perfect ovals for your woodworking projects, this shop-made oval cutting jig is an excellent solution. I built this jig specifically for creating an oval table, and it works beautifully. Here’s how you can make your own.
Building the Base
Start by cutting your base to size from plywood. While I used ¾” plywood because that’s what I had available, ¼” plywood is actually the better choice and will save you some steps later on.
Creating the Runners and Edge Guides
Mill up some scrap maple for your runners. Joint one edge and rip off the other to ensure both edges are square. Then tilt your table saw blade to approximately 10 degrees—the exact angle isn’t critical here.
Thin-rip a slice from each side of your maple piece. These angled pieces will become your edge guides. Next, rip off a third piece with the beveled edge against the fence, creating a trapezoid shape for your runners.
Cut two small sections from the trapezoid piece to serve as the pivot points in your jig. Round over the ends at a spindle sander to prevent the edges from catching on anything during use.
Installing the Edge Guides
Miter one end of each edge guide piece, then cut the other end to length. Draw centerlines on your base piece to help with alignment, then install the first edge guide with CA glue. Take extra care to ensure the first two pieces are perfectly square—this sets the foundation for the entire jig.
Use the leftover trapezoid piece as a spacer to install the remaining edge guides. Before gluing each piece, make sure the trapezoid piece slides freely through the channel with minimal side-to-side play. Work your way around the jig until all edge guides are installed, cleaning up any glue squeeze-out with a chisel.
Once all edge guides are in place, eyeball the center of the guides and transfer those lines to the bottom of the base. Add countersunk screws for extra strength—CA glue alone isn’t reliable enough to hold against the force of a router.
Making the Pivot Points
Find the center of each runner piece and drill a hole for a ¼” bolt to pass through. Trace the bolt head shape on the bottom of the runner and chisel out a recess so the bolt head sits flush with the surface.
Creating the Swing Arm
Rip a piece of plywood to size for your swing arm, ensuring both ends are square. Draw a centerline down the length and mark every inch along this line. At the drill press, drill holes at each mark so a ¼” bolt can pass through them. These holes allow you to adjust the size of your oval.
Do a test run with some paste wax to ensure everything moves smoothly.
Preparing for Router Attachment
Clip off each corner of the base at 45 degrees to prevent the router from hitting them during operation.
If you’re using ¾” plywood like I did, you’ll need to make up for the extra thickness. Cut a ¾” plywood base plate to attach to your router. Trace your router’s base plate, transfer the screw holes, countersink them at the drill press, and cut out the circle at the band saw.
Attaching to the Router
Measure the centers on your router where the edge guide typically attaches. Transfer these measurements to a piece of plywood, drill holes for the bolts, and use a Forstner bit to countersink for the bolt heads.
Important note: Assemble the jig first before taking this measurement. The edge guides create an offset, so you’ll need a wider attachment piece than you might initially think.
Cut this attachment piece to width, pre-drill for screws, and attach it to the swing arm. Clamp one side to hold it to the router while you pre-drill and screw the pieces together.
How It Works
The holes on the swing arm are spaced one inch apart, while the bolts attaching the jig to the router are longer than one inch. This setup gives you the flexibility to adjust both the width and length to create exactly the oval size you need.
With this jig complete, you’re ready to cut perfect ovals for tables, picture frames, or any other project that needs this elegant shape. The adjustability makes it versatile enough for various sizes, and the solid construction ensures clean, accurate cuts every time.
I’m the owner of Benham Design Concepts, a mixed media art studio where I design and build custom furniture and other works of art using wood, glass, stone, and various metals.
In this blog, I talk about the art I create, my journey, and the things I learn along the way.