Cutting 7" X 22" Vision Panels For Existing Solid Wood Doors - Carpentry - Contractor Talk

Cutting 7" X 22" Vision Panels For Existing Solid Wood Doors

 
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Old 05-30-2015, 05:11 AM   #1
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Cutting 7" X 22" Vision Panels For Existing Solid Wood Doors


I have to cut 7 vision panels (7" x 22") into existing 1 3/4" birch doors (wood core), was gonna make a ply template to position on door and cut with 2 - PORTER-CABLE 690LR and 1/2" shank spiral bits. The first one setup to cut just under an 1" and the second router setup to finish cut.

Does this sound reasonable? What is the smallest I can go on bit diameter before breakage becomes an issue? Is there a better way to do it?

Doors will be removed from frames.

thanks,
Bruce
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Old 05-30-2015, 07:30 AM   #2
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Re: Cutting 7" X 22" Vision Panels For Existing Solid Wood Doors


What you're looking to do sounds reasonable. I'd run a 1/2" bit with 1/2" shank to do the cutting. You mention fixed base routers, but I'd use the depth stops on a plunge router to cut 1/4" per pass or so.

If you made a mirrored template on both sides of the door, you could get away with one router just by flipping the door over and routing the opposite side and meeting the cut in the middle.

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Old 06-01-2015, 12:07 PM   #3
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Re: Cutting 7" X 22" Vision Panels For Existing Solid Wood Doors


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Originally Posted by J L View Post
I'd use the depth stops on a plunge router to cut 1/4" per pass or so.
Excellent advise, that's the way I will do it.

thanks
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Old 06-01-2015, 04:19 PM   #4
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Re: Cutting 7" X 22" Vision Panels For Existing Solid Wood Doors


I did this with 11 solid core doors. Built a nice template and tried the route, but the tearout/wandering was not good and trying to get the exact same cutout on the opposite side was impossible (for me).

method two was to use the track saw and finish the corners by hand. Very good results. I had to glue a frame inside of the cutout with mitered corners.
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Old 06-02-2015, 09:58 PM   #5
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Re: Cutting 7" X 22" Vision Panels For Existing Solid Wood Doors


Track saw and finish with a jig saw.
It may take longer to make the jig than cut the doors.
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Old 06-06-2015, 08:05 AM   #6
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Re: Cutting 7" X 22" Vision Panels For Existing Solid Wood Doors


You guys over think this stuff. It's 4 straight cuts with a regular circular saw. And finish with a jig saw. I have finished these cuts in doors with a sawzall. You have trim pieces to cover the cut. A track saw to cut 7"!?!???
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Old 06-07-2015, 06:24 AM   #7
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Re: Cutting 7" X 22" Vision Panels For Existing Solid Wood Doors


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You guys over think this stuff. It's 4 straight cuts with a regular circular saw. And finish with a jig saw. I have finished these cuts in doors with a sawzall. You have trim pieces to cover the cut. A track saw to cut 7"!?!???
for sure over thinking the easy way.

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