Smallest diameter router tool to cut a panel out

[simonfraser]

Need to cut an access panel into 20mm chipboard
the less mess it makes the better, so thin cutter but obviously don’t want to break the router cutter
dont care about the price of the cutting tool
how thin can I go and what material cutter ?
tnx

 

[Daverw]

I would use a multi tool with fine tooth blade, easy to cut clean and slow

 

[PCUK]

I'd agree with that. Use a steel straight edge as a guide.
If not then you'll probably get a 4mm bit for a standard router although I believe you can get lightweight Dremel type router attachments for use with smaller Dremel bits.
Have you considered a jigsaw with down cut blade if you can't get to the back of the panel for a clean cut?

 

[simonfraser]

tnx, yes cut a jigsaw down, which i do have
but def pipes behind but i dont know where
this looks the safe way

 

[DownWest]

My router box of bits goes down to 3mm. Good enough for most jobs like that.
Festool, nice, but pricey. Either, you need to use them a lot as a pro. Or, you like nice toys, err, sorry, tools.

 

[thinwater]

I would use a multi tool with fine tooth blade, easy to cut clean and slow

^^ This. I have used it for that and love it. Best tool for the job. Little mess, very accurate, plunge cuts, and unlike a jig saw, you can control the depth to avoid pipes and wires behind the panel (though placing a cardboard or tin guard is a good idea if they are very close).

Mine is by Dremmel. Not that many $$, and I've used it around the hose for many things. Great for removing grout, flush cutting, and even cutting copper pipe in the wall (shower faucet replacement). I use it more than the jig saw, now that I have it, though each has its strengths.

 

[KompetentKrew]

tnx, yes cut a jigsaw down, which i do have
but def pipes behind but i dont know where
this looks the safe way

You won't need the depth tool on a multitool - if you know how deep you want to go (how thick the wood is) you just stick some masking tape to the blade at the appropriate depth.

If you want to be neat with a multitool then, with a bit of practice, you can use it to lightly score a line on the wood; then the tool falls into the line when you start to make the cut.

If the cut is near an edge, like the floor or a bulkhead, then you can use a piece of scrap wood as a ruler / straight edge. But the edge needs to be well secured - due to the weight and vibrations of the multitool you can't hold a ruler in one hand and the multitool in the other - if the scrap wood rests against the floor or bulkhead then you can use it to get a neat edge in what you're cutting.

Alternatively cut or find a rectangle of scrap wood the right size and glue or screw it in place on the panel you want to cut out, and then run the multitool against its edges to make the cuts.

If the hole will be hidden and won't be seen then you can just cut it by hand. Multitools are wonderful and easy to use, but you still benefit from a bit of practice.

 

[Rappey]

Mini circular saw? Great for straight neat cutting of sheet material and can use a blade from 1mm wide.

 

[Gsailor]

Router is not terribly well suited to chip board; emphasis on "chip".

 

[Spirit (of Glenans)]

tnx, yes cut a jigsaw down, which i do have
but def pipes behind but i dont know where
this looks the safe way

Electronic instruments are available for finding pipes, wires, studs etc., behind timber and plasterboard panels. Prices between £22 and £50.

 

[simonfraser]

tnx for all the comments guys, looks like the multitool is easier to control than i thought
short jigsaw blade can bounce out in my experience
pipes / stud finder - i know they run just behind it, that's why i am so cautious, need access to the plumbing, preferably without making more of a mess of it

' You won't need the depth tool on a multitool - if you know how deep you want to go (how thick the wood is) you just stick some masking tape to the blade at the appropriate depth.

If you want to be neat with a multitool then, with a bit of practice, you can use it to lightly score a line on the wood; then the tool falls into the line when you start to make the cut. '

 

[PaulRainbow]

Alternatively cut or find a rectangle of scrap wood the right size and glue or screw it in place on the panel you want to cut out, and then run the multitool against its edges to make the cuts.

This would be how i'd do it.

Alternatively, screw a strip of wood in place, make a cut and move the strip, x4

 

[srm]

Thin cutting with a router can be expensive if using standard wood cutting bits. I managed to break 4mm and 5mm bits very quickly while cutting notches in 10mm ply (for a weaving project). Not the way for the OP to go.

 

[LadyInBed]

if you know how deep you want to go (how thick the wood is) you just stick some masking tape to the blade at the appropriate depth

Or put a wood block / batten under the head of the multi cutter to restrict the depth of the cut.

 

[simonfraser]

Or put a wood block / batten under the head of the multi cutter to restrict the depth of the cut.

yes, Makita don’t do a depth stop on their multi tools, i have a few of their toys already

 

[salar]

Really important you drill the corners or use a hole cutter then cut (my preference a plunge saw/multi tool) the sides. This is because it (a) looks far better (b) much easier to clean up the edge and (c) if there is any stress on that area, a sharp corner will create a crack point. Probably not important on chipboard (!) but would be if you were cutting a hole in GRP.

 

[penberth3]

What's wrong with a pad saw? I don't get this fascination with noisy dusty power tools for every little job.

 

[LadyInBed]

Really important you drill the corners or use a hole cutter

You don't need to with a multi saw, start the cut in the middle of the cut line, work towards the corners then use a hacksaw blade to cut to the corner.

 

[thinwater]

What's wrong with a pad saw? I don't get this fascination with noisy dusty power tools for every little job.

a. chips more.
b. great for cutting wires and hoses behind the panel.
c. slower, more dificult, and more tiring.
d. no real difference in dust, I think.

I have many trick hand saws. They get used when they are the best answer ... which is not this situation. But I might use one to cleanup the corners. And possibly a file.

 

[savageseadog]

There's the Rotozip power tool, similar in some ways to a router. The blades are small diameter.