How to Make a Ball With a Router

Routers can be used to add elaborate flourishes to finished pieces.

A router is a cross between a drill and a saw. It cuts vertically down into a wood surface by means of a rotating bit. It can be used to cut elaborate channels and trenches from pieces of wood, without going all the way through. One interesting project that can be accomplished with a router is the creation of a spherical ball. It is dependent on the capabilities and features of your router.

Things You'll Need

• Cube shaped block of wood
• Circle cutting jig
• Bench vice
• Sandpaper, varying grades

Instructions

1. Measure the available depth adjustment on your router. This will determine the overall maximum size of your ball. If your router can be adjusted from flat to 3 inches deep, your ball can have a maximum diameter of 3 inches

2. Mark a central point on top of the block of wood and measure outward by the radius of your ball. Mark a circle using the circle jig that will represent the final circumference of the ball. Make sure there is adequate wood available all the way around the ball's edge.

3. Determine the smallest increment by which you can accurately reduce the router's depth. This will determine the number of passes you will make, and the smoothness of your initial curve. Divide the radius, the center-point to edge size, of your ball by the number of increment reductions required to go from full depth to zero. For instance. If your depth-reduction increment is 1/16-inch and your router can cut up to 3 inches deep, divide the radius by 48. If your radius is 3 inches, you will make 16 passes with the router.

4. Place the wood into the bench vice and tap the circle jig into the center point of the wood block. Set the circle jig to the radius of your circle, and the router to the maximum depth. Seat the router on the jig and cut around the perimeter of the circle.

5. Reduce the cutting depth by one increment and reduce the circle radius on the jig by one increment. Cut another circle. Repeat this process until you have a stepped cone shape, leading all the way up to the center point.

6. Flip the block over and repeat the process on the other side. Trim off any excess, leaving you with a pair of stepped cones joined at the base.

7. Sand down the ridges of the steps, leaving you with a smooth ball. Use increasingly fine grades of sandpaper to create a smooth finish.

Tips & Warnings

• Always wear hand and eye protection when using power tools.

References

• Woodworking Tips: Router Circle Cutting Jig