Hi All.
I was trying to install a home-made resonator in a cigar box, but was unable to successfully cut a round hole in the box for the resonator. So, I thought I'd open this topic up as an area of discussion. I know there are a variety of techniques from using routers with a circle cutting jig and hole cutting attachments for rotary cutting tools (like Dremel tools), to drill attachments (both fixed diameter and adjustable diameter attachments (up to 200mm or 4.75")).You may know of other ways to cut these circular holes, so please add to our discussion by describing your method.
What I Tried:
As I have no router or rotary cutting tools, and the options for drills wouldn't give me the 5.75" diameter hole I needed, I decided to devise a home-made hole cutter using a small board, a screw and nut, and a carving chisel with a side facing blade. Here is a diagram of what I was thinking:
And when I tried it, it seemed like it might work okay, but as the circle cutting progressed, I broke the small board holding the knife, so I decided to do it free hand and started making sloppy mistakes, and then the hole cut through the sound board, I got rushed and broke the rest of the hole thru, splintering the sound board pretty badly. Not liking my sloppy work, I decided to remove the sound board and replace it with 2mm plywood veneer. And, I decided to hold off a while longer at building a Reso-CBG until I got better cutting holes. I did take a couple photos before things started going wrong. Here are those 2 photos:
Again, this technique could have worked if my "rotating beam" was a thicker/stronger piece of wood. What I used was a scrap of 2mm plywood veneer, and that proved not strong enough. Notice that you have to cut around and around the circle several times with a fair amount of force to cut through the sound board. When it finally breaks through, the wood will likely splinter. To prevent this you should place some scrap wood between the soundboard and your work surface. If you are working on a separate sound board that you will glue to your box latter on, this extra support won't be needed as your soundboard will be resting directly on your work surface. You also should take your time and be very patient. It's too easy to want to rush through the job and mess it up.
Well, that's all I have for now.
-Rand.
Tags:
Hi Dave,
No, I don't have a Dremel or other rotary cutting tool. I've seen them in the stores, but like routers, the million and one attachments that you can get for them has caused me to shy away from them. If I had a basic understanding of what tool bits and the like I need for CBG making and how to use them, maybe I'd go for it. There should be a discussion group about using dremel tools and maybe another for routers to discuss how these tools are basically used. I know, everyone else has access to Youtube, where there are probably dozen of these how-to videos, but I live in China where Youtube is blocked and I didn't have the foresight when I was last in the States. I will look into the Dremel and Router options. What information I find, I'll put here.
-Rand.
HI Richard.
Thanks for your input about using Dremel tools. Do you know if it takes a different kind of "drill bit" in the Dremel tool to cut a circle. I really have no experience with Dremel tools, but somehow I think it might require a different cutting tool/bit to essentially "cut like a saw". As I said before, with all the attachments, drill bits, cutting wheels, grinder wheels and other tool options, it's kind of an intimidating tool to take on as a novice wood worker. I would like to learn more, though. Could turn out to be the ideal tool for a 101 little jobs around here.
-Rand.
Hi Oilyfool
Thanks for the research. Now I'm feeling the pressure to buy. But 320 RMB ($50 US) is not a bad price. I wonder if these Dremel tool clones work with the Dremel attachments I mentioned above? Well, if not, I could always build a jig of my own, just beefier than the last one. The 110/220V power supply is definitely a plus. Thanks again.
-Rand.
HI Richard.
Thanks for your input about using Dremel tools. Do you know if it takes a different kind of "drill bit" in the Dremel tool to cut a circle. I really have no experience with Dremel tools, but somehow I think it might require a different cutting tool/bit to essentially "cut like a saw". As I said before, with all the attachments, drill bits, cutting wheels, grinder wheels and other tool options, it's kind of an intimidating tool to take on as a novice wood worker. I would like to learn more, though. Could turn out to be the ideal tool for a 101 little jobs around here.
-Rand.
Hi Richard,
When you say "they have two models", are you referring to dremel tools or hole cutter attachments? I'm not sure from what you have written. It's probably clear to everyone else who reads this, but I'm a bit slow and everything has to be clearly stated. And by "extension cord" you are referring to that long cable-like attachment do-ma-jiggy that fits between the rotary tool's bit "chuck" and the actually cutting bit. I saw a picture of one, and they do look pretty handy. I don't think many of the Dremel clone machines have those. I guess I need to shop around. Thanks for your input, Richard.
-Rand.
Rand,
I think Richard is referring to the flexible shaft attachment when he says "extension cord." And yes, the non-Dremel rotary tools available in China can be fitted with one:
http://stekolindustry.en.made-in-china.com/product/eqOnQWdGhPkA/Chi...
They are really useful for detail carving, allowing you to just use the carving tip very close to your fingers, without supporting the weight of the rotary tool motor in your hands (if you have the drill press / workstation or other supporting device).
"Somebody's goin' on a tool buyin' spree; somebody's goin' on a tool buyin' spree..."
Did I mention that in college, I was known as The Professional Bad Influence? >:-E
Oily
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