Cutting holes in finished cabinet sides (Knievel Neon Side art)

[Usul]

Hi there,

I'd like visually enhance my already finished cabinet by the great Knievel neon side art (see http://forum.arcadecontrols.com/index.php/topic,31417.0.html] [url]http://forum.arcadecontrols.com/index.php/topic,31417.0.html[/url])

I followed the mameroom plans in my build, so I can remove the upper part of the cabinet. Still, however, I am wondering what the best way is to cut out perfectly round holes on each side now, since the parts have already been put together.
A carpenter I know offered to do it with jigsaw. While he certainly has experienced hands, I am still doubting that the end result will be round enough and good looking this way.

What are your thoughts? Any alternatives you see?
As usual I very much appreciate your support.

Thanks,

[ammitz]

Could you put the cabinet on it's side, and use a router with a template?

[Franco B]

[ammitz, you replied as I was typing this ]

Definitely don't use a jigsaw to cut the finished profile.

What I would do is make a template from a scrap piece of material and then use that to template route the hole.

Route a circle to the required size in a scrap piece of MDF etc. To do this you can simply make/use a tramel like this:



You will however be doing it to create a internal ring template, not a circle like in the picture above.

Once you have a template you are happy with you can line this up on your cab side and mark the profile. Remove the template and use a jigsaw to remove the bulk of the material. You will need to drill pilot holes for the jigsaw blade to start in, be careful when drilling these so that you don't get breakout on the other side. You may need to have some scrap material on the other side to prevent/minimise this.

Once you have removed the excess you can fix the template to the cabinet profile with double sided tape, or ideally clamps if you make the template big enough. You can then use a pattern or flush trim bit (depending on which side of the cabinet that the template is) and trim the excess off.

Using this method you should be left with a nice, clean hole. I would advise practising the whole procedure on some scrap material first seeing as you are doing this to a finished cab.

[Epyx]

As FrancoB suggested this is the best way to do it. I did the same by building one similar. You can see it on the first page of my current project. I drilled holes and inserted thread inserts so I can use bolts to pivot on. The jig I created can do 6" to 15" diameter circles. at 1" intervals.

[Usul]

Hi folks,

first let me thank all of you for your great help in this! You guys rock. Special thanks to Franco for the detailled description and helpful visuals!!

One additional question: Besides the classic "Knievel neon-ring enhanced side-art" I have an additional one that should cover the entire side to the full length. Here I would need to cut out a hole, too. What would be the best approach? Should I adhere this side-art to the cabinet first and then cut out the hole or should I deal with the MDF and sideart separately?

Again thanks a lot!

[Epyx]

MDF and side art separately...do the hole first.