The hallway of our new house is quite dark so we looked at getting some windows installed. My wife found some stainless-steel portholes online which fitted the style of the door. The challenge is to cut a big round hole into a door which is 44mm thick. It needs to be reasonably accurate as there is only so much adjustment in the window.
I mentioned this on twitter and a circle cutting jig was recommended. I found this simple one from April Wilker which explained what I needed to create.
The process for making it is on her page quick and easy circle cutting jig for a router
I also found some adjustable ones so I decided to make something along those lines. After tracing the base of the router, I marked out the main slot. These are the only things you need to get accurate. I ensured this slot was parallel to the side so that I could use the adjustable fence to get a straight slot.
The slot was the first thing to cut, I clamped the MDF to the workmate and set the fence so that the router was 1mm off centre. I cut a slot using a 6mm bit then adjusted 1mm off centre the other side and cut again. This results in an 8mm slot.
Then a freehand pass around the cut-out and again around the outside. I used a surform to smooth off the rough bits.
Next up is to drill some mounting holes and to create a sliding pivot. Most people seem to use a tiny nail or point for the pivot. I’m planning to drill a hole through the door and then use a bolt to hold the jig in place. I have a selection of bolts that I could use for this but it will likely be the one on the right which has a nice smooth shank that should act well as the pivot. I may have to cut from both sides to get to the depth required which is another reason to have a drilled pilot hole.
This week I painted up the next 2 boards for the workshop benches. So I should have these up and usable by the end of the week. Having reviewed the location of the power sockets and also thought about how
At the weekend we started on a project to plant some small shrubs along the boundary to grow into a hedge. But we didn’t know what we would uncover.
It has been a busy few weeks with some key autumn maintenance jobs on the house. Primarily cleaning out the gutters. Armed with a new ladder and a standoff, I headed up to clean out the lower level gutters. Some
With the high rate of COVID-19 virus spreading around, many folks are stuck at home and all seems boring. I thought it would be great if you can get creative by building some artsy, practical DIY woodworking projects to spice
The front door on our new house is a hardwood door, it had some brass handles. These would be more in keeping with a Victorian theme than the contemporary style of the house. The handles also kept getting snagged on
I had TV aerial sockets but a very weak signal, what could be wrong? First step, find the aerial…
Fold-down beds – also known as ‘murphy beds’ are great for occasional use in spare rooms and compact flats but they have one big issue…
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