Advice on drilling large holes thro ply.

[John Brown]

Do let us know how you get on with this. I'm intrigued and might have a go myself!

 

[ChaiLatte]

That sounds like a challenge, has anyone ever managed to do that...

In addition to the good advice above, you could sand to the lines rather than rout to them. A home-made sanding drum in a drill press would do.

It could also be easier to use an inverted router and move the template around on the table. That gives you fine control and could make it easier to see the line as the body of the machine would not be in the way.

 

[recipio]

I would also use holesaws - my preference is starret and a hoover running with a crevice tool will help to clear out the sawdust and prevent burning. Clean the edges up with a sanding drum on a drill ..

 

[johnbs]

Thanks for all the advice: I might try the holesaw first as I have a set, but never tried making a 'relief' hole - good idea.
John

 

[throbscottle]

That's what I've always done.

See pic.

I wish I'd known about this long ago. My hole making will be revolutioniserated!

 

[HOJ]

Just to keep the ball rolling!

My version:



Took longer than I expected and became a bit mind numbing, not used to the random theory of the placement of holes, didn't suit my symmetrical thinking, used a combination of hole saws and a router with a bearing cutter with a shop made hole jig for the larger ones.

It is a challenge to get the ball up to the top, but I need some better hardware for the string guides as there is a bit of friction, but all the parts, so far, were found in the stash of bits.

Tried a ping pong ball to start with but it needed some weight, so next up was a golf ball, so more fun was had trying to find the blooming thing when it went through the hole and disappeared under the benches, so maybe a back/ball catcher is the next upgrade.