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Permalink Reply by Bama Hound on April 23, 2014 at 5:25am

If all you have is a jig saw you can use a metal cutting blade (as many teeth per inch as you have). Lay out your cut lines on the inside of the lid. Use the Blue painters tape to cover the outside of the lid. Then make your cuts. This will keep you from ripping paper off of the lid. When through very slowly remove painters tape.

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Permalink Reply by brdfrd on April 23, 2014 at 6:29am

Yes, use a blade with the highest tooth count you can find. Also, if you have tight curves, the blade should be shallow, front to back. The wide ones will grab the cardboard and make a mess as you cut a tight curve. You can also try cutting from the back, if you can, and clamp a piece of 1/4" plywood to the front of the box. It will prevent the cardboard from getting raggidy.

Brad

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Permalink Reply by Groucho on April 23, 2014 at 9:12am

You don't even need to use a blade.  You can use a stencil to draw the f hole(s) on the box and, then using an electric drill, drill holes along the inside of the stencil line until you can pop out the piece of loose wood.  Then use a hand file to smooth out the edges of the f hole.

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