Making Rectangular Holes in KING StarBoard - Moderated Discussion Areas

  ContinuousWave
  Whaler
  Moderated Discussion Areas
  ContinuousWave: Whaler Repairs/Mods
  Making Rectangular Holes in KING StarBoard

search | FAQ | profile | register | author help

Author Topic:   Making Rectangular Holes in KING StarBoard

froberts posted 03-23-2014 10:29 PM ET (US)
I am making a new dashboard panel on my 2004 170 Montauk. What is a good way to make the rectangular holes for switches? I tried using a drill to cut a hole then using a jig saw; the first one is not bad but not factory. Trying to cut 1/4-inch thick KING StarBoard. I am also adding a hourmeter and a receptacle for my spotlight.
jimh posted 03-24-2014 10:03 AM ET (US)
Making rectangular holes in an electrical panel has always been a problem for the do-it-yourself builder. I have used the following method:
--mark the rectangular opening on the panel workpiece
--make a circular hole with a drill at each corner, staying inside the marked lines
--use a jig saw with appropriate blade and speed to cut straight lines between the circular holes
--cut out the opening, but stay clear of the line marking the final opening
--use a file to carefully remove material from the cut line to the final line
--hope that the component you will mount into the rectangular opening will have a wide escutcheon to cover any mistakes in your cutting and filing.
If you have the luxury of working on the panel on a bench instead of in-place on the boat, you have more options. A small router might be very helpful. But, then, who has a small router around their shop but for a few semi-professional carpenters.
Plotman posted 03-24-2014 10:42 AM ET (US)
Start with a round hole and finish with a sharp chisel.
saumon posted 03-24-2014 11:16 AM ET (US)
The cut-out tools (aka drywall router or Rotozip) may be an alternative to a regular router and can be used on-site.
The DeWalt is about $60 ( http://www.homedepot.com/p/DEWALT-Cut-Out-Tool-DW660/100634645 ) but their cheaper version is $23 ( http://www.homedepot.com/p/ Buffalo-Tools-Corded-Spiral-Cut-Out-Saw-HMDSBX/203465119?N=5yc1vZc88w ).
jimh posted 03-24-2014 12:12 PM ET (US)
Many thanks to Saumon for (another) great contribution of information! That $23 cut-out saw looks like a very good tool for cutting 0.25-inch-thick KING StarBoard. At that price, you cannot afford NOT to own it.
dfmcintyre posted 03-24-2014 03:17 PM ET (US)
Have one, love it. Will be using it again when renovating the Outrage instrument panel later this spring.
Don
TransAm posted 03-24-2014 03:51 PM ET (US)
Draw your square on the piece of starboard; drill pilot holes in each corner. Clamp a straight edge parallel to the line(s) you have drawn on the work piece at a distance equal to the distance between the spiral blade and the circular guard. Insert the tool blade into the 1st hole, and ride the straight edge with the blade guard to hole #2; reposition the straight edge and repeat for other 3 sides. Nice, neat, square, straight.....
saumon posted 03-24-2014 04:23 PM ET (US)
As said by TransAm, use a guide (any piece of plywood, plank or lumber) along the base for a straight cut and adjust the speed. Too fast and the Starboard will melt.

Hop to:

Contact Us | RETURN to ContinuousWave Top Page

Powered by: Ultimate Bulletin Board, Freeware Version 2000
Purchase our Licensed Version- which adds many more features!
© Infopop Corporation (formerly Madrona Park, Inc.), 1998 - 2000.

Author	Topic: Making Rectangular Holes in KING StarBoard
froberts	posted 03-23-2014 10:29 PM ET (US) I am making a new dashboard panel on my 2004 170 Montauk. What is a good way to make the rectangular holes for switches? I tried using a drill to cut a hole then using a jig saw; the first one is not bad but not factory. Trying to cut 1/4-inch thick KING StarBoard. I am also adding a hourmeter and a receptacle for my spotlight.
jimh	posted 03-24-2014 10:03 AM ET (US) Making rectangular holes in an electrical panel has always been a problem for the do-it-yourself builder. I have used the following method: --mark the rectangular opening on the panel workpiece --make a circular hole with a drill at each corner, staying inside the marked lines --use a jig saw with appropriate blade and speed to cut straight lines between the circular holes --cut out the opening, but stay clear of the line marking the final opening --use a file to carefully remove material from the cut line to the final line --hope that the component you will mount into the rectangular opening will have a wide escutcheon to cover any mistakes in your cutting and filing. If you have the luxury of working on the panel on a bench instead of in-place on the boat, you have more options. A small router might be very helpful. But, then, who has a small router around their shop but for a few semi-professional carpenters.
Plotman	posted 03-24-2014 10:42 AM ET (US) Start with a round hole and finish with a sharp chisel.
saumon	posted 03-24-2014 11:16 AM ET (US) The cut-out tools (aka drywall router or Rotozip) may be an alternative to a regular router and can be used on-site. The DeWalt is about $60 ( http://www.homedepot.com/p/DEWALT-Cut-Out-Tool-DW660/100634645 ) but their cheaper version is $23 ( http://www.homedepot.com/p/ Buffalo-Tools-Corded-Spiral-Cut-Out-Saw-HMDSBX/203465119?N=5yc1vZc88w ).
jimh	posted 03-24-2014 12:12 PM ET (US) Many thanks to Saumon for (another) great contribution of information! That $23 cut-out saw looks like a very good tool for cutting 0.25-inch-thick KING StarBoard. At that price, you cannot afford NOT to own it.
dfmcintyre	posted 03-24-2014 03:17 PM ET (US) Have one, love it. Will be using it again when renovating the Outrage instrument panel later this spring. Don
TransAm	posted 03-24-2014 03:51 PM ET (US) Draw your square on the piece of starboard; drill pilot holes in each corner. Clamp a straight edge parallel to the line(s) you have drawn on the work piece at a distance equal to the distance between the spiral blade and the circular guard. Insert the tool blade into the 1st hole, and ride the straight edge with the blade guard to hole #2; reposition the straight edge and repeat for other 3 sides. Nice, neat, square, straight.....
saumon	posted 03-24-2014 04:23 PM ET (US) As said by TransAm, use a guide (any piece of plywood, plank or lumber) along the base for a straight cut and adjust the speed. Too fast and the Starboard will melt.