Cut rectangular hole in 30mm wood?

[bobbavet]

Gday guys

I am making desktop item such as pictured below. 140x70 rectangular cut out. Though I have a 15mm border around the cut out.

I am having trouble with the rectangular hole.

I have tried 20mm forstners in the corners then a 1/2 straight router in table. Coming in from both side by flipping. It spits at the end of a straight and gouges the next curve. Also having to adjust for every edge to get a tangent.

I tried band saw, I have to cut in from edge to start and not desirable and had trouble with cut being tangent to curve. Though it did give a nice finish.

@ a loss as to how I can do this "clean" Any tips appreciated.

thanks Bob

https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-prn2/1098082_10201285486006508_159322187_n.jpg

[Woob]

Surely a router plunging 1mm at a time if necessary wouldn't bust out at the ends? Just have to be slow and steady, and following a fence of course.

[Handyjack]

How you could try this with a band saw I am not sure. Do you require the piece that is cut out or is it waste?
Here are three suggestions. A lot will depend on what tools you have available.

1/ You could try drilling pilot hole and then use a scroll saw.
2/ If you have one, use a multifuntion tool.
3/ If you are happy with round corners, you may be able to do it on a router table, Or if brave using a router without a table. Another variation of this would be to rough cut with another method and then clean up with the router.

I am sure you will find a successful method.

[bobbavet]

Thanks guys.

I found a jigsaw at the back of my cupboard. lols

I am drilling 15mm in corners, drilling, jigsaw then using edge trim router bit in the talbe.

Surprisingly getting a straight cut.

I did have the thin 15mm edge bust out on the grain though when routing. I glued back in.

I have solved the bust out by putting a clamp on the 15mm end before routing.

This will have to do for now until I find some other method.

I reckon a jigsaw table would be the go.

[A Duke]

I would do it with a template and guide bush. Either on the router table or hand held, taking about 5mm cuts at a time. "Slowly does it"
Regards

[Dragonstaff]

Another way to stop the breakout (I guess it is the thin sides of the rectangles that are breaking off at the ends of the block) is to clamp some scrap around the sides of your workpiece, so that you are cutting/routing in the middle of a big chunk of timber, not close to the edge of the end-grain.

[lightwood]

Bob,
does the item come to you in that size, or do you make it?

If you make it oversize and use a template screwed into the waste...do all the inside work with plenty of strength in waste around the outside. Then cut it down to finished size?

Regards,
Peter

[bobbavet]

Bob,
does the item come to you in that size, or do you make it?

If you make it oversize and use a template screwed into the waste...do all the inside work with plenty of strength in waste around the outside. Then cut it down to finished size?

Regards,
Peter

Thanks for the reply Lightwood.

I have cut them to that size 170x245 and then cutting.

I am getting pretty good results with the jidg saw by the time I have rounded the edge of the hole with the router.

[bobbavet]

Gday every one, just posting my results with the jigsaw.

Here is the finished product that I will be selling.


https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-frc1/q86/s720x720/1005231_650447071641972_169763605_n.jpg

Thanks for help gents.