Cutting a door in the middle of plywood

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Forum topic by erichardson posted 07-24-2014 04:32 AM 1325 views 0 times favorited 3 replies Add to Favorites Watch
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5 posts in 1655 days

07-24-2014 04:32 AM

All, I am getting ready to build a “scoring table” for our Christian school and I need to cut a door in the middle of the plywood.

I’m using 3/4 birch, and I have plans for the build, but I’m not sure how to cut this door out. I was thinking of plunging my skill saw thru it then finishing with the jig saw…any thoughts or tips would be greatly appreciated.

This will be stained, so I need it to be a perfect cut….

If anyone near Kingsland GA has ideas, hit me up and I can bring the plans by.

-- Eric, Moundsville, WV

3 replies so far

View Dan Lyke's profile

Dan Lyke

1520 posts in 4362 days

#1 posted 07-24-2014 03:39 PM

Find someone with a plunge saw? (ie: any Festool junkies in your neighborhood?)

Barring that, then I’d consider just using a jigsaw (maybe with a fence for a cleaner cut) and a drill to make the initial cut, and plan on cutting the door out of separate stock (because the kerf of the jigsaw will be different from the kerf of the circular saw anyway).

Oooor… I have done plunge cutting by hand by carefully scraping my pull saw along a guide edge until it penetrated, and then just finished the plunge cut with the pull saw.

-- Dan Lyke, Petaluma California,

View papadan's profile


3584 posts in 3606 days

#2 posted 07-24-2014 04:03 PM

Circular saw plunge cut is the best method. Clamp a straight edge to the plywood to give yourself the straightest, cleanest cuts.

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1594 posts in 1662 days

#3 posted 07-24-2014 06:18 PM

I would consider getting some 1×2 and framing the plywood around the door, after it is cut. The door could also use some support in the same manner.

-- Brad, Texas,

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