Replies

1. 
   BArnold | Jan 11, 2005 10:22pm | #1

   Larry,

   You could use a forstner bit to drill a clean hole.  First, though, drill a perfectly straight small pilot hole all the way through the sheet.  Start drilling from one side but go only a short distance -- 1/8" to 1/4" -- then start drilling from the other side.  This process will make a clean cut through both sides.  I suppose you could substitute a good hole saw for the forstner bit.

   Regards,

   Bill Arnold - Custom Woodcrafting
   Click Here if you're interested in a good,inexpensive website host.

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   Food for Thought: The Ark was built by amateurs; the Titanic by professionals.

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2. 
   DJK | Jan 11, 2005 10:50pm | #2

   If you don't have the proper carbide drill bit use carbide pattern router bit. If it chips out drop a plastic wire grommit in the cutout.

   DJK

1. 
   Elcoholic | Jan 11, 2005 11:14pm | #3

   Ditto on the grommet.  Even if the hole is clean the exposed particle board core will look like crap and chip over time anyway.John O'Connell - JKO Handcrafted Woodworking

   The more things change ...

   We trained hard, but it seemed that every time we were beginning to form up into teams, we would be reorganized.  I was to learn later in life that we tend to meet any new situation by reorganizing; and a wonderful method it can be for creating the illusion of progress while producing confusion, inefficiency, and demoralization.

   Petronious Arbiter, 210 BC

3. 
   DDay | Jan 12, 2005 04:29am | #4

   I close friend is a plumber and whenever he cuts into fiberglass tubs, showers, or laminates he always uses a hole saw.  You make the pilot hole with the leader drill bit on the hole saw with the drill in forward.  Then switch the drill to reverse and make your cut with the hole saw.  By going in reverse, you make very sallow cuts with each pass and it keeps the saw from being too aggressive and binding on the material.  Once you get into the material enough then switch the drill back to forward and continue the cut.  Try it on a scrap peice.

    

    

1. 
   jaypoe | Jan 12, 2005 04:42am | #5

   I like using a router bit with a jig. Buy the grommet first then size the jig so the grommet fits tight. A hole saw in reverse should work but I would run it in reverse only to score the melamine (this works because in reverse the teeth are pitched down and wont blow out the melamine).

4. 
   nikkiwood | Jan 12, 2005 10:36am | #6

   The grommet is definitely the way to go -- then you can cut your hole with either a Forstner or a hole saw, or even a saber saw if the grommet is big enough.

   Just be sure to buy your grommet first, so you know what size hole you will need.

5. 
   dondownunder | Jan 12, 2005 11:28am | #7

   Larry

   Cut the hole with a hole saw then use a cable cover which cost about a buck, come in a variety of colours & are easy to fit. If your hole ends up a shade too big, glue the cover in with poly or epoxy or fix with silicone.

   Just check the largest plug size that is likely to be fed thru the hole before buying the cover. Some earlier printers had a fairly large plug & need an 85mm cable cover.

   Don

1. 
   larrmartin | Jan 12, 2005 11:57pm | #8

   Many thanks for the tips. She's choosing her grommets and we'll work carefully from there.

6. 
   Steinmetz | Jan 13, 2005 04:01am | #9

   Larry, BArnold has the best approach.
   I remove the holesaw's pilot drill (1/4")

   Drill the pilot hole as BA suggests
   with a regular 1/4" bit

   Then I substitute a similar length of
   1/4" drill rod for the holesaw's bit
   as that bit will wander and create
   an egg shaped pilot hole.
   After drilling the pilot hole and to insure
   against 'chip out' stick a patch of wide
   masking tape over the area

   Also, drill down from the top 1/3rd of the way ,
   then from the bottom up 1/3rd.
   Finally,finish down from the top.

   Save those plugs They help guide your drill
   when you dont have a drillpress to drill
   a straight vertical hole. Stein.

   
   

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   Edited 1/12/2005 11:08 pm ET by steinmetz