Author Topic: how to make this hole without router or jig saw (Read 5278 times)

online421 · « **on:** May 29, 2017, 05:25 PM »

so, how do you make this hole quickly without using a router or a jig saw?

my first attempt were Domino XL but would like to know if there is any other methods you can think of.

Thanks all

Cheese · « **Reply #1 on:** May 29, 2017, 05:42 PM »

It looks like the corners need a radius so I'd start with a Forstner bit in all 4 corners and then connect the holes CAREFULLY using a Sawzall.

WastedP · « **Reply #2 on:** May 29, 2017, 05:50 PM »

Just curious, what constraints keep you from using a router or jigsaw?

online421 · « **Reply #3 on:** May 29, 2017, 05:52 PM »

Quote from: WastedP on May 29, 2017, 05:50 PM

Just curious, what constraints keep you from using a router or jigsaw?

Its pretty simple really. I dont have a router and I dont have a jigsaw.

ear3 · « **Reply #4 on:** May 29, 2017, 05:55 PM »

Hmmm. I would plop down the money for the jigsaw on this one, even if it's just a cheap one, and then follow the forstner bit method mentioned by @Cheese . It's not like this will be the last time you'll need a jigsaw.

Quote from: online421 on May 29, 2017, 05:52 PM

Quote from: WastedP on May 29, 2017, 05:50 PM
Just curious, what constraints keep you from using a router or jigsaw?

Its pretty simple really. I dont have a router and I dont have a jigsaw.

WastedP · « **Reply #5 on:** May 29, 2017, 05:57 PM »

I'd go the other way and get a small router. Make a jig with a forstner bit and a pull saw that can be clamped to the work and routed with a top-bearing flush trim bit.

Holmz · « **Reply #6 on:** May 29, 2017, 06:12 PM »

Quote from: WastedP on May 29, 2017, 05:57 PM

I'd go the other way and get a small router. Make a jig with a forstner bit and a pull saw that can be clamped to the work and routed with a top-bearing flush trim bit.

Me too.
One would not even need the forstner bit and pull saw, just take two long pieces for the top and bottom and use two seperate got the side and screw them onto another set of boards... The diameter of the bit will determine the radius.

Or on the cheap.... drill it or Dremel it and then use a rasp.

It seems like a tool looking for a job to make the domino work

online421 · « **Reply #7 on:** May 29, 2017, 06:37 PM »

Thanks for the input guys, I may just have to get a router after all....

I had one sometime ago but find it hard to use perhaps I was not doing it right.

pixelated · « **Reply #8 on:** May 29, 2017, 09:22 PM »

You can do the long cuts plunging with a circular saw, or, since this is FOG, a track saw and finish the cuts with a hand saw or sawzall there are also handles for sawzall blades, do the corners with a forstner as mentioned. Use the saw's full depth of cut to minimize the hand work.
Another possible choice would be a multi-tool, but long straight cuts are not their forte.

Cheese · « **Reply #9 on:** May 29, 2017, 10:54 PM »

If you really want to go Neanderthal on this project, and I mean no disrespect to the OP, you can purchase a cheap Forstner bit for $10 and a coping saw frame with blades for less than $10.

I get, that sometimes it becomes more important to feed hungry children (especially when they are your own) than it is to squander cash on tools.

The downside to using the coping saw is that the cut lines will likely not be straight, and they will certainly not be perpendicular to the surface.

It all depends upon on what you hope to accomplish. The picture looks like a crib/bed and we don't know if you made it or you want to reproduce it.

Svar · « **Reply #10 on:** May 29, 2017, 11:23 PM »

Quote from: Cheese on May 29, 2017, 10:54 PM

you can purchase a cheap Forstner bit for $10 and a coping saw frame with blades for less than $10.

That would be a reasonable thing to do if you want to quickly finish the job. But this is FOG, so making a little hole in a board has to involve at least $3000 in new gear. I suggest Festool chain mortiser and a full set of Auriou rasps.

Rob-GB · « **Reply #11 on:** May 30, 2017, 12:11 AM »

Brace and bit of required size and a padsaw. Clean up using a bit of sandpaper backed up with the piece of wood removed.
It's how I was taught to cut out letterbox openings in doors as an apprentice. Old school ways never go away.

Rob.

SRSemenza · « **Reply #12 on:** May 30, 2017, 12:20 AM »

Not sure of the size and distance from the edge of the piece. But I don't think a coping saw frame would reach.

Seth

Peter Parfitt · « **Reply #13 on:** May 30, 2017, 01:44 AM »

Quote from: online421 on May 29, 2017, 05:52 PM

Quote from: WastedP on May 29, 2017, 05:50 PM
Just curious, what constraints keep you from using a router or jigsaw?

Its pretty simple really. I dont have a router and I dont have a jigsaw.

You really should get a router. To convince yourself, just compare your final efforts on this task with the sample that you showed in the picture and decide whether you are happy with your work.

Peter

Northern Early · « **Reply #14 on:** May 30, 2017, 02:51 AM »

i would probably go a different route and use forester bit and then an oscillating tools. it seems tight to mov a jog saw right there and that is where the oscillator strives.

If money is an issue id use a drill bit that i had and a plumbers saw or something that had a little more rigidity to the blade than a coping saw

As for routers i have been seeing allot of tempting 18v routers coming to the market that could go with your drill kit and be very functional. straight flute router bit, round over bit, and a bearing guided flush cut bit are by far my most used ($100 router and $60 in bits). no need for a big $400 router here.

If all of that is to much overhead, chisel and a hammer will get that done.

Bob D. · « **Reply #15 on:** May 30, 2017, 04:49 AM »

What are the dimensions of the opening, how thick is the piece to be cut, and what species of
wood (wondering how difficult it will be to cut by hand).

What is the distance to the side of the piece. It looks like there may not be enough room to work
even a small router into the lower right corner.

Do you have to make the opening on the assembled piece, or can it be disassembled or is it not
yet assembled.

Bert Vanderveen · « **Reply #16 on:** May 30, 2017, 08:25 AM »

An azebiki would do the trick. That's a Japanese 'plunge' saw (handtool). With some careful handling it would work perfectly fine.

https://www.fine-tools.com/azebiki.html

tjbnwi · « **Reply #17 on:** May 30, 2017, 08:33 AM »

Fostner bit the corners, set a guide to run the 700 along to cut the straights. The 700 is just a router that oscillates. I've cut more than a few grooves with my 500.

Tom

Pnw painter · « **Reply #18 on:** May 30, 2017, 10:11 PM »

So you have a Domino XL, but no router? I feel somewhat lost since I'm guessing that you probably have means to buy a router. Buy one and then spend some time on YouTube to help you figure out how to use it.

If you can't afford or don't want to spend the money on a router then you need to put your MacGuyver hat on. Get creative.

Sent from my iPhone using Tapatalk

antss · « **Reply #19 on:** May 30, 2017, 10:35 PM »

I'm pretty sure budget isn't the issue. The equip. in his signature easily runs in the tens of thousands of dollars.

online421 · « **Reply #20 on:** May 30, 2017, 11:02 PM »

Quote from: Pnw painter on May 30, 2017, 10:11 PM

So you have a Domino XL, but no router? I feel somewhat lost since I'm guessing that you probably have means to buy a router. Buy one and then spend some time on YouTube to help you figure out how to use it.

If you can't afford or don't want to spend the money on a router then you need to put your MacGuyver hat on. Get creative.

Sent from my iPhone using Tapatalk

I used to have a router but sold it after one use. this was purely because of the noise, I didnt like the high pitch noise generated by the router, it almost made me want to vomit after 30 minutes of use, ever since then, I never liked the router.

most of my other machinery generate a low humming noise apart from the Domino, I am ok with that.

online421 · « **Reply #21 on:** May 30, 2017, 11:05 PM »

Quote from: antss on May 30, 2017, 10:35 PM

I'm pretty sure budget isn't the issue. The equip. in his signature easily runs in the tens of thousands of dollars.

Budget is not an issue, is just the noise.

yes my equipment costed over $50K USD. I've ordered Felder F700Z recently so dont really want to spend too much on other toys as the wife probably wont be too happy.

online421 · « **Reply #22 on:** May 30, 2017, 11:08 PM »

Quote from: Peter Parfitt on May 30, 2017, 01:44 AM

Quote from: online421 on May 29, 2017, 05:52 PM
Quote from: WastedP on May 29, 2017, 05:50 PM
Just curious, what constraints keep you from using a router or jigsaw?

Its pretty simple really. I dont have a router and I dont have a jigsaw.

You really should get a router. To convince yourself, just compare your final efforts on this task with the sample that you showed in the picture and decide whether you are happy with your work.

Peter

I agree, router seems to be the answer but I just dont like the noise.

Peter Parfitt · « **Reply #23 on:** May 31, 2017, 12:07 AM »

Does the router noise still affect you when wearing ear defenders?

Peter

Holmz · « **Reply #24 on:** May 31, 2017, 07:09 AM »

Quote from: online421 on May 30, 2017, 11:02 PM

...
I used to have a router but sold it after one use. this was purely because of the noise, I didnt like the high pitch noise generated by the router, it almost made me want to vomit after 30 minutes of use, ever since then, I never liked the router.
...

I am picturing a scene out of "A Clockwork Orange".

online421 · « **Reply #25 on:** May 31, 2017, 04:34 PM »

Quote from: Peter Parfitt on May 31, 2017, 12:07 AM

Does the router noise still affect you when wearing ear defenders?

Peter

Yes, but limited. problem is I dont always wear my personal protective gear such as ear defender/goggles. I should have.

Holmz · « **Reply #26 on:** May 31, 2017, 06:50 PM »

Birdhunter · « **Reply #27 on:** June 05, 2017, 03:35 PM »

Lots of good advice so far.

I'd make a quick trip to my Festool dealer and buy a 1400 router, a set of template guides/bushings for the router, a 3/4" straight cut router bit with a 1/2" shaft, and a Festool dust collector. I'd go to a gun store and buy some high quality ear protectors with built in hearing aid technology. Good hearing protectors shut off in high sound but let you hear normal sounds, like the radio.

Then, home and build a template to guide the router. I would build the template in 4 sections. Two straight and two curved sections joined with Dominos. The template dimensions allow for the bushing offsets.

I'd practice on a piece of scrap taking shallow cuts with the router while wearing eye and ear protection. I wouldn't plunge the router bit, but cut out a good size hole in the wood and start the router cut with the bit already set to the desired depth remembering to take multiple shallow cuts. I use double sided tape to affix the template to the wood.

Remember to consider the spinning direction of the router bit. You do not want to cut in the direction where the router bit pulls the router. That can get hairy in an instant.

Once satisfied, I'd tackle the job with confidence.

This way, you get the job done neatly and justify some new toys.

Gregor · « **Reply #28 on:** June 09, 2017, 05:23 AM »

Quote from: Birdhunter on June 05, 2017, 03:35 PM

I'd make a quick trip to my Festool dealer and buy a 1400 router, a set of template guides/bushings for the router, a 3/4" straight cut router bit with a 1/2" shaft, and a Festool dust collector.

In case budget is no issue and the dealer has it available: also get a MFS

Tim Raleigh · « **Reply #29 on:** June 10, 2017, 11:15 AM »

Quote from: Rob-GB on May 30, 2017, 12:11 AM

Brace and bit of required size and a padsaw. Clean up using a bit of sandpaper backed up with the piece of wood removed.
It's how I was taught to cut out letterbox openings in doors as an apprentice. Old school ways never go away.

Definitely separates the men from the boys...love your posts Rob!
Tim

Holmz · « **Reply #30 on:** June 10, 2017, 08:30 PM »

Quote from: online421 on May 29, 2017, 05:25 PM

so, how do you make this hole quickly without using a router or a jig saw?

my first attempt were Domino XL but would like to know if there is any other methods you can think of.

Thanks all

I am going to give you high marks for creativity.
It obviously worked, and I would not have considered it myself.

Well done sir!

Cheese · « **Reply #31 on:** June 10, 2017, 10:08 PM »

Quote from: Svar on May 29, 2017, 11:23 PM

That would be a reasonable thing to do if you want to quickly finish the job. But this is FOG, so making a little hole in a board has to involve at least $3000 in new gear. I suggest Festool chain mortiser and a full set of Auriou rasps.

Ya...ain't that the case...

online421 · « **Reply #32 on:** June 11, 2017, 04:54 PM »

Quote from: Birdhunter on June 05, 2017, 03:35 PM

Lots of good advice so far.

I'd make a quick trip to my Festool dealer and buy a 1400 router, a set of template guides/bushings for the router, a 3/4" straight cut router bit with a 1/2" shaft, and a Festool dust collector. I'd go to a gun store and buy some high quality ear protectors with built in hearing aid technology. Good hearing protectors shut off in high sound but let you hear normal sounds, like the radio.

Then, home and build a template to guide the router. I would build the template in 4 sections. Two straight and two curved sections joined with Dominos. The template dimensions allow for the bushing offsets.

I'd practice on a piece of scrap taking shallow cuts with the router while wearing eye and ear protection. I wouldn't plunge the router bit, but cut out a good size hole in the wood and start the router cut with the bit already set to the desired depth remembering to take multiple shallow cuts. I use double sided tape to affix the template to the wood.

Remember to consider the spinning direction of the router bit. You do not want to cut in the direction where the router bit pulls the router. That can get hairy in an instant.

Once satisfied, I'd tackle the job with confidence.

This way, you get the job done neatly and justify some new toys.

Thanks Birdhunter.

I will do exactly what you laid out above, gonna get the 1400 Router, bushing/template and a 800mm glide. I need to watch some clips about the router bit pulling router.

online421 · « **Reply #33 on:** June 11, 2017, 07:14 PM »

Quote from: Holmz on June 10, 2017, 08:30 PM

Quote from: online421 on May 29, 2017, 05:25 PM
so, how do you make this hole quickly without using a router or a jig saw?

my first attempt were Domino XL but would like to know if there is any other methods you can think of.

Thanks all

I am going to give you high marks for creativity.
It obviously worked, and I would not have considered it myself.

Well done sir!

Thanks buddy. it is actually quite easy and fast to do with the Domino, I built a template and work my way along it, similar to router technique I suppose. Just had to do it slow to ensure good finish.