Woodworking / Router Jigs?

[Scuba Steve]

I'm trying to figure out the best way to cut three rectangular windows into a blank door slab. The best way I could come up with to do this is with some kind of jig that a router would attach to that can be clamped to the door in order to keep the cuts straight. Does this sort of thing exist, or is there a better way to go about doing this?

[HardDrive]

Are you planing straight cuts all the way through? If so, I would drill holes at the corners of each window hole, the use a jig saw to cut between. You can clamp a piece of wood along the cuts to keep the saw from straying outward. Go slow and use a new sharp blade.

[dad911]

I am assuming it is a flat door with veneer. And the 'windows' you are installing have trim, so the cuts should be close, but don't need to be perfect?

I would puts strips of blue painters tape on both sides of the door in the area of the cuts and press it down firmly to prevent chipping. Mark cuts, use a circular saw, finish the corners with a hand saw, jig saw, or sawzall.

[javadog]

Dremel....

[sc_rufctr]

The tool you're describing does exist. You can see it at the top of this photo.
It has an adjustable clamping system so it can be clamped at the ends of the work piece.
The glass of Coke is on top of the stop piece.

If you go to a good tool shop I'm sure they'll have something similar.

I used it to guide a router to cut the holes for a sewing machine table I built July last year.

[javadog]

I would drill the corners (a little inside of where you really want them), cut the holes with a jig saw, then trim the edges with a router, if you want them to be precise. The window trim should cover the edge, but it doesn't hurt to make it nice. You can use any straight edge to guide the router, or make a template, if that is easier for you.

JR

[Scuba Steve]

Thanks! I know comparatively little about woodworking but am hoping to learn a thing or two. I planned on having trim of some sort on both the inside and outside of the windows but wanted to be as neat as possible with my cuts so I don't run the risk of ruining the door. Windows will be reeded glass - I've already sourced some double paned ones from a local glass supplier.

I do plan on making this from a wood veneered, solid core door. Basically the kind readily available at Home Depot for about $60 or so. A few companies make them premade, but they start around $2,000 and go up from there so if I do end up scrapping one I still come out pretty far ahead. I can handle the trim and finishing, but haven't tried cutting anything precice in something like this before. I appreciate the suggestions! Here's the layout.

[MBAtarga]

Is this to reproduce what I consider that retro/vintage look for a house front door with 3 small windows diagonally placed across the upper portion of the door? (edit - your post and picture appeared after my question)
If using a router - I'd cut a template for a pattern following router bit of the appropriate depth and clamp it to the door in each of the three positions.
The other option would be to mark the cutout positions and use a jig saw (Bosch or equivalent). As someone above posted - I'm assuming the cuts do not have to be perfect, as the "window" trim would cover the edges.

[sc_rufctr]

Originally Posted by Scuba Steve

Thanks! I know comparatively little about woodworking but am hoping to learn a thing or two. I planned on having trim of some sort on both the inside and outside of the windows but wanted to be as neat as possible with my cuts so I don't run the risk of ruining the door. Windows will be reeded glass - I've already sourced some double paned ones from a local glass supplier.

I do plan on making this from a wood veneered, solid core door. Basically the kind readily available at Home Depot for about $60 or so. A few companies make them premade, but they start around $2,000 and go up from there so if I do end up scrapping one I still come out pretty far ahead. I can handle the trim and finishing, but haven't tried cutting anything precice in something like this before. I appreciate the suggestions! Here's the layout.

Using the tool I bought for my router would make this relatively easy but it was about $100 total.

[look 171]

You will need a pretty big HP router to do that cut in 1 3/4" door (exterior?). Drill four holes and cut away with a jig saw. Like someone said here, the trim will cover the ugly cuts from the jig saw. Don't over think it. If it has to be exact, then make a jig and use a long flush trim bit. Still, I trim as close to the cut line with a jig saw to prevent burning of the router bit.

[slodave]

I'd over think it...

[look 171]

All right smart ass. Now that you are over thinking it got me thinking about you. I do have a pretty large piece of African Mahogany at my job site saved with your name on it. Its about 70" x 8-9" wide. There are a few pieces of smaller ones you should be able to use. As long as I know that its going into those pretty round things you are making, then you are more then welcome to have it.

[slodave]

Not being a smartass... I'd over think it.

Yes, please! Assuming that the thickness is good, yes, into shift knobs.

[look 171]

Originally Posted by slodave

Not being a smartass... I'd over think it.

Yes, please! Assuming that the thickness is good, yes, into shift knobs.

S2S, straight lined. The grain is very,very straight on this board. I bought the whole piece for a small drawer front someone scratched. I think it should be 13/16" thick. Will it work for you?

[slodave]

A bit thin, but I should be able to get three layers on resawing it. If it's as straight grained as you say, should not matter when stacking 6 layers. The 8/4 13 board ft I just bought was very straight grained as well. I like patterns, light/dark grain, but I also like reusing/repurposing wood when possible.

[slodave]

Bringing the thread back 'round... Jeff is right, no need to waste a router bit cutting through all that. Drill holes, jigsaw inside the line, route to the line to have a nice finish. Jigs are your friend. To be a bit more anal, draw the lines, and instead of rough cutting with the jigsaw, set up a guide fence and cut more accurate lines. If after that you really need to clean things up, run it through the router.

[dyount]

Easy peezy.....

Step 1 make a jig out of 3/4 MDF that is exactly what you want size wise. Make the jig oversize length wise to be able to clamp to the door
Step 2 Cut out roughly using a good jigsaw to about 1/8 from the finished opening
Step 3 clamp jig to door and use a bearing over type 1/2 shank by X length flush cutting bit to clear the opening.

You may drill a small hole in the corner prior to routing in order to more easily square the inside corner.... Use a rasp/riffler to get a nice square inside otherwise moulding installed will be difficult to seat.

[Flat Six]

Originally Posted by dyount

Easy peezy.....

Step 1 make a jig out of 3/4 MDF that is exactly what you want size wise. Make the jig oversize length wise to be able to clamp to the door
Step 2 Cut out roughly using a good jigsaw to about 1/8 from the finished opening
Step 3 clamp jig to door and use a bearing over type 1/2 shank by X length flush cutting bit to clear the opening.

You may drill a small hole in the corner prior to routing in order to more easily square the inside corner.... Use a rasp/riffler to get a nice square inside otherwise moulding installed will be difficult to seat.

FTW!

You don't want to have to set up a clamping straight edge to rout these window openings; you'd have to get the clamping just right (measured properly and square) 12 times -- 24 if you have to rout the openings from each side. Virtually guarantees window openings won't be square . . . .

[dyount]

FTW?

If the rectangle is laid out on the MDF jig and put on the door square , clamped I guarantee it will come out perfectly. Using separate straight edges for each cut with a router or cutting it out freestyle will not work as well. IF a bearing over router bit rides on your template there is no offset of measure and you will get a cut exactly like the template.

Although as someone who used to build custom doors/windows in a mill, master carpenter/master cabinetmaker and college professor teaching those subjects I FTW have no idea of what I'm talking about.

[dyount]

LOL............ I'm a fool. I thought it was F' The What