How do I make my trackball hole?

[spOOf]

I am using the U-Trak without bezel.  So I need a 3 1/4" hole.  How do I make this?

The tools I have on hand are a router, jigsaw, drill & circular saw.

I need to cut through both MDF and plexi.

Thanks!

[Ed_McCarron]

Get someone to make you a router template for the 3 1/4" hole.

[Franco B]

Get someone to make you a router template for the 3 1/4" hole.

[Ed_McCarron]

Get someone to make you a router template for the 3 1/4" hole.

I keep waiting for the little smiley guy to flip me the bird.

[Epyx]

You mentioned having a drill...another options is this:

http://www.homedepot.com/webapp/wcs/stores/servlet/ProductDisplay?langId=-1&storeId=10051&catalogId=10053&N=5yc1vZ1xhc&R=100495375

That is what I used to make mine (2 7/8" size for my trackball).

[drventure]

That holesaw worked great for me.

It cut a perfect hole in the formica I used.

Cutting through MDF and LUAN board was tougher, thought. I found that cutting a little, then backing off and vacuuming out the particles helped a LOT. Otherwise, the teeth tend to clog up.

[Franco B]

Hey sp00f. I made you a 3.25" ID router template if you want it. Just pay shipping and its yours 

[spOOf]

Wow, very cool!  How would I use this?

The idea I had before checking back in here was to create a jig for the router.  I still may do that but this definitely looks sweet.

Shipping would be to 19428.

[Franco B]

Trace the inner diameter of the template onto your CP.

Drill a hole inside it big enough to get your jigsaw in

Jigsaw the material on the inside of the traced line leaving about 3mm (1/8") or so.

Screw the template to the CP and then use a flush trim bit in your router and let the bearing follow the template.

One perfect 3.25" circle, job done

I'll need your full address (PM me) as I'm in the UK but int. shipping should only be about $4 or so.

[severdhed]

i used a 3.25" hole saw for my utrack....worked like a charm.  it fit perfectly.  you need to take your time, but it will work great.  the way i did it was pre drill the center hole with a small drill bit.  the attached the hole saw and started cutting..just long enough for it to score a 3.25" circle into the MDF...then with my forstner bit i drilled a 1 1/8" hole right inside the edge of the hole. (that makes a small hole for the saw dust to fall through, which makes it go much smoother.)  then just put the hole saw back on and drilled the rest of the way though.  then used a flush trim bit in my router to cut the hole in the plexiglass.

[rEd86]

I posted this in another thread but it is relevant to this conversation.  Here's the jig I used for cutting the hole in the wood top for the Electric Ice-T track ball I just mounted in my build.  It replaces the base of a router and does a great job of cutting a perfect circle from 1" to 7.5" in 1/16" increments. (for those here in the US)

It's the Jasper Model 400 Router Circle Cutting Jig and sells on Amazon for less than $22. Your local Rockler store might also carry them.




It is easy to use and a versatile tool to have if you need to cut various size circles in wood.  A must have for anyone with a router.

--Ed

[Epyx]

Any videos of this in action? I would love to see it being used, cause looking at it im still scratching my head...

[rEd86]

I'll see if I can't record something - it's really easy to use once you figure it out.  (it took me a second as well & I had it in hand )

--Ed

[smalltownguy]

+1 on the video. I'd like to see it too.

[Disgrntld]

Any reason you guys use 3 1/4"? I just made mine 3" and it seems like the trackball will fit fine.

[smalltownguy]

Ultimarc's U-Trac has a slightly larger neck than the Betson or Happ trackballs. This was done intentionally to allow the ball to sit higher in the assembly.

Thus, the need for a 3 and 1/4" opening

[javeryh]

Any videos of this in action? I would love to see it being used, cause looking at it im still scratching my head...

 

The large holes are for the screws to secure the thing to the base of the router.  They put a bunch in there to accommodate various brands of routers.  The small holes are for the pin which the router pivots on to make the hole (you need to drill a pilot hole for the pin in the center of the circle you are cutting out. 

The numbers 1 through 7 you see are inches for the radius of the circle you want to cut - the small holes are in a spiral pattern from number to number increasing the hole size by 1/8" each step.  For example, if you wanted to cut a 5-1/4" hole you would locate the 5 and then follow the line from the 5 until you got to the one marked 1/4" which is where you would place the pin.  It is easier to see in person.

[spOOf]

Ultimarc's U-Trac has a slightly larger neck than the Betson or Happ trackballs. This was done intentionally to allow the ball to sit higher in the assembly.

Thus, the need for a 3 and 1/4" opening

Correct. I used a 3 1/4 forstner bit to do mine as they had a special on them when I was picking up a router bit.

[severdhed]

Ultimarc's U-Trac has a slightly larger neck than the Betson or Happ trackballs. This was done intentionally to allow the ball to sit higher in the assembly.

Thus, the need for a 3 and 1/4" opening

Correct. I used a 3 1/4 forstner bit to do mine as they had a special on them when I was picking up a router bit.

thats a big forstner bit!!!

[spOOf]

It's HUGE!

I'll probably resell it at some point since I only used it for this one hole.

[Epyx]

The large holes are for the screws to secure the thing to the base of the router.  They put a bunch in there to accommodate various brands of routers.  The small holes are for the pin which the router pivots on to make the hole (you need to drill a pilot hole for the pin in the center of the circle you are cutting out. 

The numbers 1 through 7 you see are inches for the radius of the circle you want to cut - the small holes are in a spiral pattern from number to number increasing the hole size by 1/8" each step.  For example, if you wanted to cut a 5-1/4" hole you would locate the 5 and then follow the line from the 5 until you got to the one marked 1/4" which is where you would place the pin.  It is easier to see in person.

Thanks

[Franco B]

I take it you dont want the router template I made for you then? I'll offer it up in the free items thread in that case.

[spOOf]

I take it you dont want the router template I made for you then? I'll offer it up in the free items thread in that case.

Yep, sorry.  I really appreciate you making it.  Was making a return at the local woodworking shop and saw the forstner bit while I was killing time during the return. 

The forstner bit worked well, but I think this would work great also.  One question I'll toss outer there about the template... wouldn't this put 4 screw holes on the top of your panel?  I assume you then just fill them in?

Hopefully someone will get some good use out of it.  Thanks!

[Franco B]

No worries, just thought I would offer.

That thing must be huge!  Bet it takes some torque to cut with it, what did you use?

As regards to the template you could use double sided tape or the screws. I thought I would give you both options. If I'm doing a CP for someone and have to use screws I always fill them with wood glue and sawdust to make it look pretty, even if it will never be seen again.