cutting the corners for over/under coin door

[llama]

I'm cutting out the hole in my front panel for the Happ over/under coin door, which has 1 inch radius curve corners.  The book says to mark 1 inch up from each corner and then use a 1 inch hole saw to cut the corners.  If its a 1 inch radius curve, then shouldn't a 2 inch hole saw be used?  This may just be a typo in the book. Unless I'm mistaken, a 1 inch hole saw will produce a 1/2 inch radius curve.

[llama]

Well, if anyone is interested, I ended up cutting the corners with the 2 inch hole saw.  Ultimately, it probably wasn't necessary to try to be that exact, since the over/under door has a 1/2 overhang.  If I had to do it again, I would just draw out the outline of the door with the curved corners, and then cut it out freehand with a jigsaw.

[AtomSmasher]

If I had to do it again, I would just draw out the outline of the door with the curved corners, and then cut it out freehand with a jigsaw.

Thats exactly what I did, which worked out well because of the half-inch overhang.

[DaveMMR]

I totally messed up the curved cutouts of my coindoor and it completely doesn't matter since, as stated, it's covered up.  You could even go square if you wanted to.   The only time you may want to do it properly is if you're front is a door and having people see an imperfect cut will bother you.

[ChicagoDave]

I used "squared off corners" and had the problem of seeing 4 tiny holes at each corner since the coin door was actually rounded.  I ended up having to repair this by cutting 4 corners off of a piece of MDF and hot glued them into the corners of the holes.  I then used wood filler to fill the gaps and sanded the whole thing down.  After paint, the problem was fixed.