Now we’re embarrassed that we couldn’t come up with a solution as eloquent and easy to use as this circle cutting router jig which [Grays42] built. He’s using a small trim router for the job.

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This quick and dirty angle grinder circle cutter certainly fills the bill, and makes decent cuts in sheet metal to boot. The build starts with an unlikely source for parts – an old automotive AC ...

For the circle cut, I place the rafter on sawhorses and use the 3-foot pattern board to trace its edge onto each rafter's ends. Using the jigsaw as before, I cut the circle.