cutting out door

[1213brett]

I am making the the project bellow. I want the yellow door to fit nicely and not show a guide hole. What is the best way of accomplishing this? Is it to cut the door on the inside of the pattern line and the side wall of the car on the out side of the pattern line? Or maybe to cut both on the line then sand door way and out side of door to fit?

 

 

 

Edited June 30, 2017 by 1213brett

[jollyred]

Cut out the doorway, trace it onto another piece of stock.  Cut the door slightly large and sand to fit.

[JTTHECLOCKMAN]

I would use a very thin blade and just cut the door out. You do not want it too tight anyway and any imperfections are matched with the cut. Want real thin blades use a small jewelers blade.(00 or even 000 )

[hawkeye10]

Brett that is a good question and I bet you have some good answers. When you finish this project post a picture. I really like stuff like this. 

[CharleyL]

I would find the smallest drill bit that I can get the blade to fit through by drilling holes in scrap and increasing the drill bit size and then testing to see if the end of the blade of choice will fit through it. A very tiny plade size would be best for tmaking this cut. A larger blade or blades can be used for the rest of the project. Then I would carefully drill the starter hole in the project with that drill bit. I would choose a location, like the sharpest corner of the pattern piece  to drill the hole, since perfectly square cuts are rarely ever perfectly square anyway.. Usually. this method will result in a completely invisible starter hole after the piece is cut and a little sanding is done. The result will be a piece that is one blade width smaller than the opening all the way around, but shaped perfectly to fit without sanding. Very careful sizing and placement of the access drill hole is the only critical part of this.

The alternative is to use any drill bit and cut out the pattern hole  out of the original piece by closely following the pattern lines with the blade cutting directly on the pattern line and discarding the cut out piece, then cutting a second piece by also cutting along, but directly adjacent to the outside of the pattern line and then sanding the edge of this piece to fit perfectly into the hole in the original piece. If done perfectly the piece being inserted will be about half the thickness of the blade too large all the way around, but should require a minimum of sanding to perfectly fit the hole in the original piece. Following the line very accurately will be required to do this option.

Charley

 

 

[tuner]

I would go with the smallest blade & bit drill on the line and the hole will almost disappear. If your perfectionist will.. make 2 holes were the hinges would be cut out the door.