Thread: Drilling Square with Holesaw into Door - HELP!

I use this for Forestner bits but should work also for holesaws.
Get a piece of scrap 2x4 material. Using a drill press, drill a square hole. Next, clamp the piece over the work, align and then insert the hole saw and use the hole as the guide

Hi Shaun

This what you need to drill holes square in your door. Catalogue - Drilling - Drilling Accessories Its the second last item on the page. After drilling the holes what you need to do is with an electrical circular saw is to do plunge cuts rather than using a jigsaw because a a circular saw blade is much more rigid than a jigsaw blade. The trouble is that the grain of timber can run a jigsaw off square.

To make the plunge cut it would be better to nail a piece of timber to the door for each cut to press the toe of the saw plate against to hold it steady.

After doing one side of the door I would then turn the door over and then run the cut towards your hole saw cuts and then finish it off with the jig saw.

Depending on the type of dog door it should have finishing flanges on it to hide any rough cuts.

Just as another tip when drilling with hole saws through solid core doors is to drill a about a 3/8" hole on the perimeter of the hole saw cut. What this does is allows the saw teeth on the hole saw to clear and stops the burning and clogging of the hole saw teeth.

Have you thought about using a router with a template to square the hole up!!!

If you could post a picture it would help us to visualise the problem.
in the meantime here's a couple of suggestions.
It should still be possible to fit the door and make the job look neat.
Perhaps you could add some timber moulding around the fitted dog door to hide the crooked cuts and any gaps.
You could use something like plastibond or builders bog to fill the gaps. It can be easily cut or worked after it sets and before it goes rock hard.

I'm with Yawally. I'd also consider the router to sqaure it up. Photo of the problem will help. If it's a 35mm or whatever door it may need to be done both sides, but you could use a straight bit with a template guide from one side for half the depth, then a flush trim bit from the other side for the other half. Neaten up with a sharp chisel.

Originally Posted by steck

It should still be possible to fit the door and make the job look neat.
Perhaps you could add some timber moulding around the fitted dog door to hide the crooked cuts and any gaps.

We have a saying in the trade , "if you can't hide a join , make a feature of it "
..... " if you can't hide the f-up , make a feature of it " also works

Originally Posted by Manuka Jock

We have a saying in the trade , "if you can't hide a join , make a feature of it "
..... " if you can't hide the f-up , make a feature of it " also works

Yep, a number of options.

First trim and square the hole with a strait cutter in the router.

Next, line the hole with wood molding to make it a feature. (size of hole MINUS thickness of molding EQUALS size of doggy door.)

Perhaps you might have to go to the next size larger doggy door. Inadvisable, as most people over-estimate the size of the door anyhow.

Cheers

Graeme

Is it a plastic dog door? There should be considerable coverage around the perimeter of the door to cover an imperfect hole. I can't imagine how it could be so out of square to expose the cut actually.
If being out of square makes the hole too small, just rasp it out til it fits. If being out of square exposes the cut on one side it makes no sense to square up the edges, it will just expose the cut on the other side as well. If this is the situation, just run a small wooden beading around the perimeter of the door.

Cheers
Michael

Shaun, I know how you feel - I've had similar 'difficulties' using a jig saw in thick material.

A jig saw is the right tool to use but it requires great care. Ensure that you are using a suitable blade, in this case I would suggest as course as you can purchase. When cutting, just guide the blade to and along the line - do not push and particularly ensure no lateral force on the blade at anytime which is what probably contributed most to the outcome you describe. Take it slowly.

When using the hole saw cut half the depth from both sides. It stops breakout occurring and can help minimise the out of square effect that you experienced.

Good luck

In terms of what went wrong, this is my take:
1. for the holesaw part. There are broadly two kinds of hole saw - ones with a long central drill bit and ones without. Drilling a hole in a door freehand, you want the former sort. First, drill a pilot hole right through, and then if you are satisfied with that mount your hole saw in the drill and go ahead. The central drill bit will follow the pilot hole. Drill half way through from each side. This will give you a nicely squared hole, even if you do it with your eyes closed.

2. for the jigsaw, I'm suspecting you forced the jigsaw a bit hard. Beginners typically do - you should be aware that they are at their best when cutting thin plywood etc, so using them in a solid core door would demand patience.

Did you use the right tools? Yes, you did.

How to fix it. Well you havent explained exactly whats wrong with the job. Is the problem that the hole is ragged and in some places is wider then the dog door plus whatever flanges it has to hide the cut ?

Incidently, Barry White's tip about using a drill to provide a relief hole at the perimeter of the hole saw cut is a ripper ! Never heard it before.

Arron

Originally Posted by Arron

Incidently, Barry White's tip about using a drill to provide a relief hole at the perimeter of the hole saw cut is a ripper ! Never heard it before.

Arron

Yep , that's a good old tip .
Some holesaws have tungsten tipped teeth that by their very nature clear the dust as they go. Some don't , and clog , especially when drill-cutting MDF style sheets . They also heat and burn .
And the pilot hole , top tip too .


And take your time

Hi
Keep in mind for future reference ......there hasn't been a jig saw been made that will cut square when you need it to.

From what I can pick up from what you are saying....You have cut the hole too big/too ragged for the bought doggy door. How would you go reducing the opening to the proper dimensions by cutting some flat aluminium and screwing that flat on each face of the door. in doing so you end up with the right sized hole to fit the doggy door and cover up any evidence of any problems. Any hardware store will sell you aluminium flat (say 40mm X 3mm), then mitre the corners together for neatness
This will be the same effect as a timber mould but being only 3mm thick and more rigid it will mean you can fit the doggy door directly to the ali and not run into thickness problems that could occur with a timber mould

Another thing to remember is...Tradesmen make the same mistakes as apprentices, but the tradesman can get out of it quicker

Originally Posted by chambezio

...Tradesmen make the same mistakes as apprentices, but the tradesman can get out of it quicker

A skill usually learnt as an apprentice in the heat of battle , endeavoring to remedy things before the grouchy foreman saw the damage

Originally Posted by chambezio

Keep in mind for future reference ......there hasn't been a jig saw been made that will cut square when you need it to.

Gunna have to dispute this one, my Jigsaw will cut square and cut a straight line, its all about feed rate, control and using the correct blade to suit the job on hand.

My brother had the exact same Jigsaw as mine till he wore it out from not using it correctly, but he could never get it to cut as well as mine did and it all came down to the points I've raised above , correct feed rate, control and most importantly, correct blades to suit the job on hand

Once I showed him why he couldn't do it, he woke up to it and he can now cut a square and straight line now