Cutting the 3" hole for trackball..... router?

[LeedsFan]

I'm thinking of buying a router for my new panel project. I can get a decent one from B&Q for £40. I can't really justify it for a one off project but people say they are fantastic tools so I might just bite the bullet and get one.

However..... I'm a complete n00b with woodworking really and have never used a router before. Can it be used to accurately cut the 3" hole for the trackball? Thing is I will have to buy a 3" hole cutter for my drill with the correct mandrel. Those two parts together come to about £16 at my local B&Q.  (B&Q is same as your Home Depot in the States)

If a router can do that hole just as good then I will probably invest in one and not bother with the hole cutter for the drill. I will be cutting the hole through 0.5mm sheet aluminium and 3mm thick plexi. The aluminium will have the artwork already stuck to it so that I can get the exact positioning for the trackball hole. I'd rather do it that way than try to match the artwork over the hole. Only thing I'm worried about is how "clean" the cut will be. I don't want the artwork tearing around the edge of the cut as that would just look crap. (Artwork will be from Scott at Mamemarquees if that makes any difference).

[Jdurg]

The router will completely tear up your artwork at the edges.  I wouldn't suggest cutting it that way. 

A router is an amazing tool and I am so glad I bought one.  Like you, I had almost zero woodworking experience before starting on my CP, and recently picked up a router, jigsaw, and a shopvac.  Even if you don't end up using a router and just use a hole saw (which is honestly what I would reccomend since it does take some practice to fully control a router), getting a router is a great investment.  It can recess, groove, clean up ragged cuts, etc. etc.  Well worth the investment.

But for cutting this 3" hole, I'd just get a hole saw with a lot of teeth in it and cut the hole slowly.

[mangrovejack]

You can use a Jasper Jig to cut a perfect hole with your router.  I use one all the time for my car audio and home audio speakers when I need to make cut-outs or trim rings.

[Mr Wilson]

i got this one cheap enough

http://www.screwfix.com/prods/16987/Drill-Bits/Holesaws/Holesaws/Holesaw-76mm

and you'll need this to hold it

http://www.screwfix.com/prods/12437/Drill-Bits/Holesaws/Holesaws/Quick-Hitch-Holesaw-Arbor-11mm;jsessionid=00K2SYI130UKSCSTHZOCFFA?ts=43013

[pacmandude]

A router is a versatile tool and can be used for this application; however, many inexperienced router operators make a real mess of their first attempts because a router takes some time to learn to control (dancing bits, etc). I would use something else until you become proficient with the tool.

[leapinlew]

I used a practice hole as a template with a flush trim bit to cut the real deal.

[javeryh]

If you set everything up properly you can use the mounting plate as the template to cut the hole with a pattern bit - just make sure the mounting plate is exactly centered on the ball bearing. 

Get a piece of scrap, cut out a hole bigger than the trackball but smaller than the plate (you can make it as sloppy as you want).  Then drill the holes for the mounting plate extensions/screw hole things and drop the plate into the scrap wood - make sure it can't slide around at all in your scrap piece.  Then just clamp the scrap piece in place and use the mounting plate as your guide.

[FhM]

B & Q is very expensive compared to the likes of Screwfix. Get all your gear from screwfix as it is next day delivery. I used them about 5 times last year and everything came next day (even the one I did after 4 pm)

[shardian]

You can use a Jasper Jig to cut a perfect hole with your router.  I use one all the time for my car audio and home audio speakers when I need to make cut-outs or trim rings.

That thing is pretty damn neat. The wife's step father has gotten into building custom speakers, and he can't stop bragging about the router circle template.

[brock.sampson]

When I made my hole for my track ball I originally tried to use the mounting plate as a guide but couldn't get the bearing to ride on the plate and cut the plexi at the same time.  I actually chewed up the mounting plate and the router bit a little.  I ended up buying a cheap 3" hole saw drilling a hole in a scrap piece of wood and using that as a guide for the router.  If I just used the hole saw I don't think the plexi cut would have been nearly as clean.  I would highly recommend buying a router I have used it on many projects since building my cab.

[Trebeck]

I used a drill press with a 3" wood Cutting bit.  It took a long time to do it and it was very nerve wracking.  The cut was very clean since i had the plexi strapped down tight.

I think I'll try the router next time.

-Beck

[shardian]

I would not use a hole saw for this. With a drill press, then maybe. Definitely not with a regular drill though. If you get lucky and the saw doesn't skip on you, then the hole will most likely be at an angle.
What you can do is use a hole saw in some 1/4" hardboard or similar to make a template. Then you just have to secure the template and go to town with the router.

[nantom]

If you use a drill... Make sure everything is secure and tight, you are standing with the drill vertical, and clamp some scrap 1/4 inch plywood real close to the hole on both sides.  This will cause all the damage to be made on the scrap ply, and not to the finish wood, formica, MDF, or lexan.  Go slow and pull the bit out often after the initial cut to clean the junk off the teeth.  Best bet is definitely a drill press in my opinion.

[thatitalian]

B & Q is very expensive compared to the likes of Screwfix. Get all your gear from screwfix as it is next day delivery. I used them about 5 times last year and everything came next day (even the one I did after 4 pm)

My router was half the price at B&Q (as it was on sale) for exactly the same item.

I used a practice hole as a template with a flush trim bit to cut the real deal.

I agree. Use the mounting plate as a guide to make a template in mdf, then use the template clamped down the the control panel and a flush trim bit to make your hole. KEEP THE TEMPLATE, just in case you make another one..... and believe me, you will!

[Paulson]

I'm thinking of buying a router for my new panel project. I can get a decent one from B&Q for £40. I can't really justify it for a one off project but people say they are fantastic tools so I might just bite the bullet and get one.

However..... I'm a complete n00b with woodworking really and have never used a router before. Can it be used to accurately cut the 3" hole for the trackball? Thing is I will have to buy a 3" hole cutter for my drill with the correct mandrel. Those two parts together come to about £16 at my local B&Q.  (B&Q is same as your Home Depot in the States)

If a router can do that hole just as good then I will probably invest in one and not bother with the hole cutter for the drill. I will be cutting the hole through 0.5mm sheet aluminium and 3mm thick plexi. The aluminium will have the artwork already stuck to it so that I can get the exact positioning for the trackball hole. I'd rather do it that way than try to match the artwork over the hole. Only thing I'm worried about is how "clean" the cut will be. I don't want the artwork tearing around the edge of the cut as that would just look crap. (Artwork will be from Scott at Mamemarquees if that makes any difference).

I don't know if it's to late yet but...you could get a template printout of you CP
on any paper and just line it up that way...mark all the hole positions & chop them
out...then when you get your new CPO it should be bang on...

[Blanka]

Everyone is talking about 76mm. That is 3 inch yes, but for my 2.5 inch trackball, the hole is 48mm as the ball's center is lower than the cp. Guess the visible size of a 3 inch ball is also slight less than 76mm.