cutting out square holes

[therogdoc]

Sure this has probably been covered before but cannot find it so:
How do you cut out squares in a board - the cutout has to be fully enclosed within the board. The corners have to be square. Would prefer to use a router or TS (not a jigsaw). So what I want to do is cut 16x36 inch square holes in larger boards.
Thanks in advance.
Roger.

 

[RONWEN]

It sounds like the squares are cut through the board(s).  What size are they?

 

[therogdoc]

Sorry - they are 16inches by 36 inches. Yup - cutout of solid 4/4 board (mahogany)
Thanks

 

[RONWEN]

Sorry - they are 16inches by 36 inches. Yup - cutout of solid 4/4 board (mahogany)
Thanks

Sounds like plunge & stop cuts with the TS and carefully finish the corners with a jig saw would work fine.  That's quite a lot of timber to chew through with router bits.

 

[Brice Burrell]

Sorry - they are 16inches by 36 inches. Yup - cutout of solid 4/4 board (mahogany)
Thanks

Sounds like plunge & stop cuts with the TS and carefully finish the corners with a jig saw would work fine.  That's quite a lot of timber to chew through with router bits.

I like Ron's advice here.  Maybe a hand saw over the jig saw if you prefer. 

 

[junk731]

I had a project last summer that had similar requirements. Used an OF1400 and the MFS on a couple of the cutouts but found using the TS55 and guide rail method Ron mentioned a lot easier.

John

 

[jacko9]

Rip the board in three pieces then cross cut out your square hole and use your domino joiner to index the boards to glue up flat.