Cutting out complex shapes. What tool?

[Effayy]

Well, my birthday is rapidly approaching, and I have need of a new tool, I just don't know which one I need yet.. That's where I'm hoping you'll chime in.

My goal is to cut out a complex shape in the middle of my side panels.

[lesserChance]

There is a router attatchment for dremel tools, but I would think that an actual router would be the best way to go.  They are a lot easier to handle than the smaller dremels.

[Effayy]

There is a router attatchment for dremel tools, but I would think that an actual router would be the best way to go.

[whammoed]

There is a router attatchment for dremel tools, but I would think that an actual router would be the best way to go.

[jjd]

A scroll saw would probably work quite nicely to 'connect the dots'.

[Nannuu]

If you want it to look really nice I'd suggest buying a bushing guide set for your router.

[Dexter]

I've a rotozip thats handy enough for cutting comlex shapes. Its no precision tool though.

Dexter

[PetitMorte]

You may also want to consider a jig saw.  They are very good at curves and angles, and you could use it to cut out most of the hole stuff before using a dremmel for the itty bits.

[SteveJ34]

When it comes to dremels or rotozips, there are always differing opinions.

I use my dremel for many different tasks but when it comes to precision cuts and the handling required to accomplish it, its just not the best tool unless you have some sort of jig.

My experience in such situations particularly with MDF is the dremel tends to have a mind of its own much like a cat, child, or teenager in terms of where it wants to go when.

For the something as intricate in design as the example you outlined, a scroll saw would probably serve best but how you accomplish that on something as large as a arcade side piece might be a bit trickly.

An alternative might be to cut out a hole in the cab side then do your design on a seperate piece of material and fit that into the hole you cut, patch and paint.

....or mount it from inside for some "depth".

Just an idea.....

Steve

[Jabba]

Definately a scroll saw *could* do the work on something that intricate. MDF is pretty hard though, so it might not work. Typically you use a scroll saw to carve out thinner (1/8 to 1/4 ") stock.

That being said, I used my scroll saw to carve out the profiles for Cub Cars (12 in total) for the kids a cubs. This was basically a 2" piece of pine. Scroll saw got though it, but I had to change the blade every third car and had to go slow. I'm sure it would work for your pattern.

[wintermute]

I agree with Nannuu, and SteveJ.

[Effayy]

Excellent ideas guys, thanks!

So far here's a step-by-step of how I propose I can do this, after following your advice:

1. Route a circle in the side of my cabinet.
2. Route out a smaller circle (which will be the inset) in a seperate peice of MDF
3. Use a scrollsaw to cut out the intricate design on the peice from Step 2.
4. Glue the inset into the routed circle on the cabinet side
5. Laminate over the entire side of the cabinet
6. Use a drill and a dremel tool to route out the laminate covering from the "inner" side, so the laminate will follow teh same countours as the scrollsawed peice.

Sound like a plan?

I'm curious to know if simply gluing the inset will be adequate, or should I find a way to screw it in place as well?

- FA

[mccoy178]

One of the best things I've used to hold guides in place is an 18 gauge air nailer.  I also found for straight cuts, I use whatever length of 1x4 and small nails to tack it to my working surface.  Brad nails don't come back out of the guide piece very easily at all(which sucks when you want to use it over and over), and the tiny nails can be tapped back into the board making it smooth for the next use.  Clamping can work as well, but it is sometimes easier just to fill in the tiny holes on a paintable surface that it is to deal with a long run of wood.

For cutting circles, I bought a jig from a local woodworking store that attaches to the router face and lets you cut whatever size circle you need.  I build poker tables, and I found this quite handy with odd size cup holder requests.

BTW, the router with a bushing will make that laminate as flush with the wood as the day is long.

[wintermute]

Glue when done properly should be stronger than solid wood, so I would think you should be all set with just glue for getting your "inset" in place.

wm

[Nannuu]

The router (or Dremel) can only take out so much of the laminate.  On the sharp corners you'll have to do that by hand with a blade.

[nostrebor]

If you use a scrollsaw for cutouts they make some nifty sandpaper that you can load in the scrollsaw for smoothing the cutout. It makes the sanding step much easier, and is nice for sneaking up on fine detail.