Cutting T-Molding Slot with only hand tools

[grunger106]

Hi

First time poster, but long time lurker...

Recently bit the bullet and started my first project a bartop based around an X60 Tablet PC.

Got the case built and it looks pretty good I think, but as I live in a flat, I don't have any real space to work or a bench with vice so I'm limited to a power drill on the power tools front...

I've got the case done with hand saws, but I'm not sure how to go about cutting the slot for the 15mm tmoulding without power tools.

Can this actually be done? Or is a router the only way?

Thanks

[P-chan]

I've heard people have had mixed success with carefully cutting the spine off the T-molding and gluing it to the wood edge with some industrial epoxy.

[grunger106]

Thats not a bad idea!

When you say epoxy, any particular brand?

Here it is so far, need ideas for a bezel too, but that I guess is a whole other thread

[P-chan]

I don't know if a brand was mentioned, but I would suggest something that will adhere well to plastic as well as wood.  I would err on the side of overkill i.e., 2-part epoxy which is really strong.  Make sure you are ok with sanding off any excess and use plenty of clamps or something until it's set.

[kahlid74]

Yeah, the above two options are what I would do.

Either procure a dremel with a saw extension or find a similar cutting disc for your drill and TAKE YOUR TIME.

Or cut the spine off, and use either an epoxy for super strong or liquid nails/gorilla glue with the idea that you may have to reapply again a couple years down the road.

[yaksplat]

With the amount of time that would take, and the potential for screw ups on your project, you'd be better off picking up a cheap router from craigslist.

[P-chan]

With the amount of time that would take, and the potential for screw ups on your project, you'd be better off picking up a cheap router from craigslist.

This, or do what I did : borrow a router and buy the slot cutting bit.  I just posted up on facebook and over email and asked if anyone had a router I could borrow and had three offers in a day. 

[grunger106]

Thanks for the answers all

I don't have a problem in getting a router, but don't you need something a bit more study than a dining room table to work on with one - thats my problem, I don't have anywhere to use one....

Maybe the cut of the spine and use no-more-nails will work...

[yotsuya]

My last countertop, I fully assembled it sans paint and artwork and just laid it on its side on the ground in my backyard and zipped the router around the whole thing.  Flipped it, and did the other side.  2 minute job.

Didn't you almost cut your nuts off, too? Or was that with a different tool?

[yotsuya]

Safety first!

[P-chan]

My last countertop, I fully assembled it sans paint and artwork and just laid it on its side on the ground in my backyard and zipped the router around the whole thing.  Flipped it, and did the other side.  2 minute job.

Didn't you almost cut your nuts off, too? Or was that with a different tool?

Stay on topic.

I'll take that as a YES!   

It's what I plan on doing with mine, so......

[yaksplat]

I was actually drilling a control panel hole on a board across my lap

Worst idea ever.

[grunger106]

Nearly loosing ones nuts to a powertool has to be a mind focuser!

I've got some epoxy so will give that route a shot, if it doesn't work out then its pretty non-distructive - so I can think again.

Thanks for the input all

[grunger106]

Well, the EPoxy route didn't work so well, even stapling the strip with the stuff bonded didn't really produce a nice looking result, funnily enough it looked like someone had tried to stick t molding to a cab

So I ripped it off and for the parts it would work for carefully cut a groove using a tennon saw, and for the part next to the screen used a cutting bit on a b+d rotary tool

Just waiting for the new piece to arrive to install it.

Moral of the story (as always I guess) - don't try and cut corners - do it propery...

[Unstupid]

Moral of the story (as always I guess) - don't try and cut corners - do it propery...

Yet you are still using a tenon saw instead of a router.... 

[grunger106]

Fair point, but in my defence I live in a 3rd floor flat, with no outdoor space, in the middle of a city.
I'd love to have a garage with a vice/table and router, but right now that isn't an option....
So I'm doing the best I can with what I have right now 

[kahlid74]

Well, the EPoxy route didn't work so well, even stapling the strip with the stuff bonded didn't really produce a nice looking result, funnily enough it looked like someone had tried to stick t molding to a cab

So I ripped it off and for the parts it would work for carefully cut a groove using a tennon saw, and for the part next to the screen used a cutting bit on a b+d rotary tool

Just waiting for the new piece to arrive to install it.

Moral of the story (as always I guess) - don't try and cut corners - do it propery...

Did you utilize a clamp system?  Was the epoxy mixed properly?  Was the spine completely cut or did you leave some r eminence?  I've done the epoxy route and it can look pretty close to the actually cutting the slot, but it takes a lot of time, patience and careful hands. 

[Los Abrazos Rotos]

My brother cut the 'T' from his t-moulding and glued it in place with clear flexible superglue.  Its still on 3 years later and you would honestly never know the difference.

[P-chan]

Fair point, but in my defence I live in a 3rd floor flat, with no outdoor space, in the middle of a city.
I'd love to have a garage with a vice/table and router, but right now that isn't an option....
So I'm doing the best I can with what I have right now 

If it's a bartop, you'd be best served borrowing/renting a router, and buying/borrowing a slot cutter.  Carry the thing outside (it's not a full cab, take advantage of that fact) and do it in your parking spot.  If you have a decent router and a sharp slot cutter, you won't need a vice, just maybe one or two clamps.  The router should buzz through it like butter, and it will literally take you 5 minutes to do the whole thing.

[grunger106]

I suspect I didn't have enough clamps when I tried to do the gluing to be honest
However, the tennon saw+ the cutting blade on the dremel style tool worked a treat, T-Molding now installed and looks pretty good
When I get a bigger place and go for a full size cab, a router will be on the top of my shopping list.
Thanks for all the help guys