Cutting Out Doors...Router or Jigsaw.....

[GPW]

For routing with a 1/4" bit and no bushing , we just make the jig out of thicker material (3/4" ) and let the bit shaft (not the cutting part) ride on the jig edge... May be impractical for really large jigs ..

[Rock]

Gage,

Try this: http://www.whitesiderouterbits.com/catalog.html#catimgs

Look under "Flush trim, downcut, spiral, solid carbide." I've got their 1/4" and I also see they have an 1/8" solid piloted bit. Nice.

My walls are stick framed with plywood applied both sides. So I was careful in framing out my door opening, and then used a Roto-Zip to cut out the door blank (Roto-Zip being essentially the same as a router with the 1/8" piloted but from the link above.) I somehow managed not to butcher it, so the door blank I cut out became a perfect grain match door skin with only a 1/8" gap door to wall.

Eric