Quote:
Originally Posted by lincpimp
There is no way to cut an inside hole with the bandsaw as the blad is just a big circle, no ends to speak off.
I have a really nice dewalt jigsaw, and I use that with a metal blade to cut the inside holes. It has a foward/backward oscillating action that helps the blade cut smoothly and quickly. I start buy drilling a hole large enough to get the jigsaw bade thru, and then go to town. I finish it up with a round bastard file for the corners and a flat file for the sides. If I have some notches to cut I usually use the file to do that. A good bench vise is your friend during the filing process, and some decent gloves while you cut is a good idea to hold the parts steady on the bench.
I maybe have $250 invested in cutting/filing tools to do this, but I can make just about anything, and they are also good for wood and plastic projects too. Recently used the badsaw to cut up pvc couples to make my new bathtub fit. Tools that will last a long time with proper care and use.
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Oops yah I was thinking of a jogsaw when I wrote that last comment. Thanks again, looking forward to the finished product!