how to make this hole without router or jig saw

[online421]

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]

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]

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.

 

[Stone Message]

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

Peter

 

[Holmz]

...
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]

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]

 

[Birdhunter]

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]

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

 

[tiralie]

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]

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]

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... [big grin]

 

[online421]

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]

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.