The video “Best Way to Cut an Oval || Cool Router Jig” is by Bourbon Moth Woodworking. In this engaging video, Jason shares his process for transforming a rough, glued-together slab of two-by-fours into a perfectly flat surface and then demonstrates how to create an elliptical jig to cut out a flawless ellipse.

It all started when Jason received a hefty slab from a friend who had attempted to make a table top. Unfortunately, the slab was far from ready; it was bowed, curved, and too large for his planer. But fear not! Jason had a clever solution in mind: a router sled. This method is perfect for anyone facing similar challenges with oversized lumber.
Building the Router Sled
The first step was to construct the router sled. Jason began by ripping down some pieces of three-quarter inch plywood. These pieces were cut to a height that would allow them to act as rails for the router sled to glide along. He cleverly joked that instead of calling it a router sled, it should be termed a “router train” – and thus, the router train was born!
Once the rails were clamped to the table, Jason ensured they were level and free of any bow. He then measured the base of his router and cut out a piece of plywood to create a sled that would accommodate it. The sled was designed to keep the router securely in place while allowing it to slide smoothly.
After coating the inside of the sled with paste wax for smooth operation, Jason set about finding the lowest point of the slab to establish a reference for flattening. This method ensures that minimal material is removed. With the router powered up, he made passes back and forth, effectively milling the slab flat.
Flipping and Finishing the Slab
With one side of the slab perfectly flat, Jason flipped it over to tackle the other side. He secured it in place and went through the same process of identifying the lowest point and milling it flat. The satisfaction of transforming an ugly slab into a smooth, usable surface was palpable.
After both sides were flat, Jason moved on to sanding the edges to ensure a clean finish. But wait! He had almost forgotten about the elliptical jig he planned to create. This jig would be instrumental in cutting the perfect ellipse from the slab.
Creating the Elliptical Jig
Jason explained that while there are commercial jigs available, they often lack the capacity for larger surfaces. Thus, he decided to build his own. The first order of business was to determine the dimensions based on the slab’s width. He cut out a perfect square to serve as a base for the jig.
Next, he crafted the xy top pattern by ripping down plywood at a 13-degree angle to create dovetails for the sliding pivot points. Jason humorously noted that while he may not know all the technical terms, he understood how to make it work. The jig was designed to allow smooth movement while cutting the ellipse.
Final Adjustments and Cutting the Ellipse
After assembling the jig, Jason made some final adjustments to ensure everything was square and functional. He attached the router arm and set it up to cut the ellipse. After marking the desired points and adjusting the jig, he was ready to begin the cutting process.
As he started cutting, Jason’s enthusiasm was evident. He likened the experience to a choreographed dance, smoothly guiding the router along the jig. However, the thickness of the slab posed a challenge as his bit wasn’t long enough to complete the cut in one pass. So, he finished the cut with a jigsaw, ensuring precision by following the groove left by the router.
The Final Product
With the ellipse cut out, Jason was pleased with the transformation. From a rough hunk of two-by-fours to a beautifully shaped piece, the slab now had the potential to become an eye-catching tabletop. He rounded over the edges to soften the look, completing the project with a touch of finesse.