Useful tools and techniques

[Peter Daniel]

Originally posted by jag

For when the God himself seeks help from mere mortals

Actually I was teasing you guys a bit to grow some interest before I post technique.

Chris, I believe you don't have any connection with the "company" what so ever, otherwise you wouldn't recommend the product. (just couldn't resist the joke) While Rotozip might be good for some jobs, I grade it at the same level as Dremmel tools which means light hobby tasks.

UrSv and hifiZen were on a right track because both forms and router were used. Here are all 11 of them, done in 6 hours.

[Peter Daniel]

I usually promote using of woodworking tools on aluminum and I had good results so far. Aluminum is pretty soft and when proper care is taken most metal jobs can be done without milling machine. Here is my setup.

[Peter Daniel]

Because those covers suppose to be used in commercial display units (at the shows) so everything had to be done to the highest standards and material shouldn't get scratch in a meantime. I decided to make some forms out of particle board and MDF. The forms were used both to draw the cutout outline as well as the guide for the router bit. Also as a protection when cutting out the hole with a jigsaw and moving the piece on a table.

[Peter Daniel]

After rough cutting out the opening with a jig saw, I placed the piece over the first form, then put the second one on top and I'm ready for milling (or rather routing)

[Peter Daniel]

Here is a closup of router bit in action, I didn't noticed any dulling, but then the marerial was only 1/16" thick.

[Peter Daniel]

Here how the edge of a cutout looks. In my book it's as fine as it comes for job of that type. Just smoothing the edges a bit with viksen file and scotch brush and that's it. No additional finishing required.

[Peter Daniel]

And here is my trusty router. I have it mounted permanently on Ryobi table saw. Comes handy any time.

While that job had not much in common with stereos, technique used here might be incorporated in many other applications. Just use your imagination and don't be afraid to experiment.

[Peter Daniel]

I like that picture too.

[UrSv]

I was thinking about routing around the edge and knowing your feelings for the "edge trimmer" bit I should have guessed. As for the jig-saw I suspected it might have too much ripping action to actually produce a nice edge but when used at a distance from the finished edge and combined with the router it seemed to work out nicely.

Great work. Now where do I find a place other than my kitchen to do this type work?

/UrSv

[Peter Daniel]

Balcony? When I was living in an apartament I was using the table saw right there even in winter. Didn't get any complains either.