Expert: Jamie Yocono - 1/16/2008

Question
I need to cut hand holes in a box to move it around. I've drilled two holes and connected them which give me the right shape but my accuracy with hand and jig saw sucks. There's got to be an easy way...

Answer
Hi Tony,

You're right, there HAS to be a better way to accomplish those oblong holes. Here's are two suggestions.

First, if you have a router (a plunge router is best, but you can do it with a fixed base router), you can accomplish those holes in a snap. Mark where you want the hole to start and end. Then, either clamp a straight edge to guide the router base, or use an edge guide attachment and make the cuts. If your router has a fixed base, you will need to turn the router on, then lower the bit into your wood.

I know, most router manufacturers will cringe reading that, but if you hang onto it, you can manually plunge the bit into the wood. I usually tip the router, lifting one side of the router up so that only one edge of the base is touching the wood- but the bit isn't toughing the wood.  That's hard to explain, but you're resting one part of the base on your wood, and then turn it on.

Anyway, depending on the thickness of the wood, I would make the cut in 2-3 passes, dropping to bit down a little more each cut to take away more wood. You will need to use a straight bit, that is- one with no bearing on the end. There are many versions of straight bits, the best to cut this is one with a spiral cutter on it, not the ones with just two carbide "teeth" on it. The spiral router bit makes a cleaner cut, as well as gets the sawdust out of the way better. But either one will work.

That's the best and simplest way to cut one of those holes.

Another way is to cut your two holes, like you did before, and rough cut it, just like you did. But to clean them up, use either a coarse file to straighten the two straight areas, or use a sanding spindle to sand them straight. This method isn't perfect, but a file or a sander will do a decent job of fixing the long straight areas where your blade wandered.  I'm only suggesting this in case you don't have a router.

OK, hope this helps, write back if you have any more questions. Good luck,

Jamie Yocono
Wood It Is! Custom Cabinetry
Las Vegas, NV
www.wooditis.com