Cutting a small rectangle out of an assembled MDF cabinet - what a pain!

[javeryh]

Anyone have any ideas on how to do this?  My cabinet is completely finished (painted and sealed) but I decided to put a plug recepticle on the back instead of just a round hole and the plug from my SmartStrip hanging out of the back.  All I had to do was cut a rectanglular hole 1-1/16" x  1-13/16" out of the back panel to accept the plug recepticle.  It has taken me almost 2 hours and I'm still not finished.  After laying out the hole I started by drilling out as much material as possible using a large drill bit in each corner.  Then using a very small hand saw I connected the holes to remove most of the material.  That wasn't so bad - what has been excruciating has been trying to square everything up to the lines.  I've been using a metal file but it is very slow going.  I imagine a chisel would work a little better but the hole is so small I couldn't get one of my chisels in there to really do anything.  I thought this would take 5 minutes - I want to scream!

[ChadTower]

This is why a lot of receptacles have cover plates.

[shardian]

Use a dremel and a barrel sander attachment.

[ChadTower]

NiteWalker:  shoulda routed it out with a custom template and just chiseled the corners.

[Kaytrim]

I took and drilled holes for the corners and then used a jigsaw to finish it off.

TTFN

[ChadTower]

It's a valid method but would have been easier with a flush trim saw or keyhole saw.

[shardian]

It's a valid method but would have been easier with a flush trim saw or keyhole saw.

Yeah, but why buy those tools when you can do the job just fine with tools on hand?

[ChadTower]

Because he'd rather spend 5 minutes than 3 hours?   

Any woodworker should have a decent flush trim saw, IMO.  Short money for a real timesaver that increases quality of work.  Makes cutting dowel tips off a very clean process.

[javeryh]

I did use a keyhole saw - it takes forever to cut through MDF.  I actually sped up the process by using the blade for metal cutting instead of the one made to cut wood.  There wasn't room for the flush trim saw to fit in there.   

[ChadTower]

A flush trim saw is narrower than a keyhole saw... but possibly not strong enough to cut 3/4" MDF without help, now that I think about it.

Buy a jigsaw, maybe? 

[javeryh]

I have a jigsaw and a router but there was no way to get the tool in there either (believe me, I tried).  The side panel of the cabinet sticks out 3/4" from the rear panel so there wasn't enough room to maneuver the tool.  Plus, I was working on a finished surface that I didn't want to scratch by running a power tool over it.  I wish I had a pic to show what I mean... I'll snap a few tonight.

[ChadTower]

I think I get it... external obstructions that wouldn't let you maneuver the jigsaw body.

A case of adding a requirement after the cab was glued, yes?

[javeryh]

I think I get it... external obstructions that wouldn't let you maneuver the jigsaw body.

A case of adding a requirement after the cab was glued, yes?

You got it.  I'll definitely be cutting this out pre-assembly on the next one!

[mountain]

I've been using a metal file but it is very slow going. 

Try using a wood file..

Seriously though, this tool would do wonders for your situation.

[ChadTower]

A meat carver!

[Chris]

I think the best advice came earlier... mount the outlet in a regular electrical box and use a coverplate so the rough cut doesn't show.

[Xiaou2]

Use a Dremel with a spiral blade
(rotozip style bit)

[BobA]

Use a Dremel with a spiral blade
(rotozip style bit)

Good idea.  Do you use spiral bits made for a Dremel or the Rotozip type?

[Xiaou2]

I dont think Rotozip bits fit inside a Dremel.   However, there are
spiral bits made for the dremels.   One was included with a
Multi-Tip kit I bought a while back - which I believe was produced
by Dremel.

 I have also used a 1/4" Spiral Bit from Rotozip, that fits inside
a router.   Works great for quick holes... as it eats thru MDF
like a hot knife thru butter.    Much easier, faster, and better control
than using a jigsaw.   

 And before that,  I hooked the smaller regular Rotozip bits into
a hand drill..  and put the drill into a drill guide assembly.  This
also worked decent...  tho not as nice as the Router.


 If you want a very clean PRO edge however,  you would probably
need a straight edge and a guide base...

  Or cut within a mm of the edge and use other tools.   As sometimes the
bits tend to wander.

 Well, at least the larger ones did.   I havent used the dremel
one yet,  as Ive only needed to cut larger holes such as
for speakers - which didnt need super precision.


 EDIT:

 Wow - The 1/8"  Rotozip bits Do fit into the Dremel I have.   
Tho - I noticed that the Dremel spiral bit had a tighter spiral,
and was a little shorter.   This may help to maintain a better
cutting line.   

 The kit that had it, has 220 pieces, and is by dremel.  Got it
at Home Depot.   It includes a circle cutter w/ straight
edge adapter.

 And BTW - These bits also zip thru plastics and Plexiglass without
shattering it.   So you can make all kinds of crazy design cuts with them
if you really wanted to.