May 28,  · Cutting a Circle in Wood with a Hole saw Using a hole saw is the absolute easiest way to cut circles in wood for your project. All you have to do is lock your hole saw in the chuck of your drill or drill press and start cutting. You can use hole saws to cut circles from ¾ inches up to 7 . The most common way of cutting circles in wood is using a plunge router with a circle cutting jig. Now, you can buy a circle jig to fit your router, like this one, or you can make one yourself out of 1/4 inch plywood. I used my bandsaw to shape it, but this step is optional. Cutting out circles on a band saw with a jig works on the same principle as the disc sander method. The workpiece turns on a pivot pin, and rotating it into the saw blade cuts a circle. If you need a quick, simple circle jig, start with a 3/4" plywood base roughly the size of the band saw table with a miter slot cleat glued to the bottom.

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