Need help making a jig cutting 2 1/4 inch aluminum plate

I made some for my wood bandsaw. I used the wood bandsaw to cut them out.

Thanks Dan, I probably will do the same, but with all the real good experts here I figured someone will give up a secret or so...I appreciate your help......Peter

Dan's suggestion will work very well. Make a layout of the circle, then saw to the outside line, leaving only a few thou to sand. If you have a vertical belt sander with a table, it's real easy to turn out a very respectable piece of work sanding to the remaining line. Use a divider to make your layout. You can then layout the slot required for the blade, and saw that after sawing the circle. Unless you have a sanding belt you don't want, make sure you use a metal cutting one for the aluminum. It will pull the abrasive off the typical belt intended for sanding wood.

Harold

I turned a rod to correct OD on the lathe, parted it off a skoach thick and surface ground it until it fit perfectly for thickness.

If you have a belt or disk sander you can bandsaw it pretty close to the line but leaving a tiny bit of material outside the line, and then sand it to the line by eye and it will look pretty dang round.

Grant

PeterM wrote:

If you have a decent set of hole saws you could cut the blank with a hole saw nearest to the size of the blank and then sand it to fit.

Stuart