I'm working on a giant Connect 4 game and need to cut 42 evenly spaced 6" holes in a 1/2" MDO plywood sheet. I'm considering two main options: using a 6" hole saw or a router with a circle cutting jig. I've used hole saws before, but never for holes this big, and I'm worried about achieving the right precision and controlling the saw. On the other hand, I've never used a router jig either, and I'm concerned that a trim router may not have enough power and might slip. What's the best approach for consistent, precise results for all 42 holes?
3 Answers
A 6" hole saw can be tough to handle; it can get unwieldy and hard to control. Consider using a router with a template along with a bushing. That should help keep your cuts aligned and make it easier to manage. Just make sure to use a straight edge for accurate hole spacing!
I suggest using a router with a circle template. It can give you the precision you need, especially if you make sure your template is sturdy. Just be prepared for the center to become loose, and ensure the router is well stabilized to prevent it from slipping out as you finish the cuts.
If you're looking for precision and have access to a CNC machine, that could be the easiest way to go. It might save you a ton of time and effort, and you'll get exactly the holes you need without the hassle of manual cutting.