I'm looking for advice on how to cut a 4-1/4" hole in a 1.5" thick, 6"x6" piece of plywood. I have a 4" hole saw, but I'm unsure about how to deal with the remaining material after using it. I also have a palm router, a larger corner router, a battery-powered jigsaw, and a coping saw. Has anyone here used a router on plywood before? Any tips or techniques would be greatly appreciated!
5 Answers
I frequently use a rabbeting router bit to expand holes in plywood. Just take shallow bites around the hole for best results. Don’t forget to make a template or the process could get slow if you have to do multiple cuts. You can also clear out a lot of material with a jigsaw beforehand to make it easier!
I suggest using a jigsaw. I’d leave the 4" hole saw out of it. Just trace your circle and drill 4-5 small holes within the circle to help guide your cut.
If your hole saw isn't the right size, it might be tricky. You could use a router attached to a center point, but keep in mind that you’ll have to make several passes due to the depth. Alternatively, if you're comfortable tracing a perfect circle, a jigsaw can work well!
Yeah, I think the jigsaw would be more manageable for a clean cut. Good luck!
You can start by using the hole saw to cut the initial hole. Then, use a rabbeting bit on your router to widen the hole to about half the depth. Finally, take a flush trim or patterning bit on the router to finish the hole. If you don’t have all those bits, alternatively, consider getting a 4-1/4" hole saw to make it easier!
Hey, this is a great excuse to grab a 4-1/4" hole saw! It’s perfect for cutting holes in drywall for recessed light fixtures too. Plus, the more tools, the better—right?
Thanks for the tips! I might give the jigsaw a shot since I’m already tracing it out.