Teardrops n Tiny Travel Trailers

I really want to cut my doors to reflect the radius curves on the windows that I'm going to install in the door. Essentially the door is going to be the window with a narrow frame around -- just enough to install the needed hardware. However, I'm just a little nervous about cutting that curve. A rectangle cut with 90degree corners would seem to be easier. I just got a router and it seems as though I could cut the curve on the router using the window as a template if I buy the correct bit - is there one????. Any suggestions as to the best/easiest way for me to go. If I rout the door can I use a bit that will cut right through the 3/4 inch ply without tearing up the face or backside? Any tips?

This is my window---

thanks Philip

You could try a 1/8" straight bit......just go slow....

Micro469 wrote:You could try a 1/8" straight bit......just go slow....

How long should the cutting area be? --- 1"?
Philip

Not sure what you mean by that.... I was thinking more along the lines of using your window as a template and using the router base against it. That would give you about 2 1/2 to 3" around your window I think.. Depends on how big you want your door....

Micro469 wrote:Not sure what you mean by that.... I was thinking more along the lines of using your window as a template and using the router base against it. That would give you about 2 1/2 to 3" around your window I think.. Depends on how big you want your door....

I mean on the cutting bit should it be about 1" long -- the part that actually does the cutting so that it would go right through a 3/4 inch board at one time?
Philip

A 1" bit would be good, but I would do it in multiple passes AKA Steve F. That way the router doesn't have to work so hard and is probably easier to control....

Philip...DO NOT make the cut in one pass...on 3/4, I would make 2 or prefferably 3 passes...I would be lerry of using the window as a template, unless I was sure I could clamp it securely in place with no chance of breaking the window(expensive mistake)...you could draw out what you want, cut it close with a jig saw and finish with a sander...there are lotssa methods for making a radius jig for a router or building a template...it all depends on your skill/comfort level with the tools you have...a router, can mess up a lotta stuff in less than an eyeblink if not carefully used...even for the experienced...
madjack

Micro469 wrote:A 1" bit would be good, but I would do it in multiple passes AKA Steve F. That way the router doesn't have to work so hard and is probably easier to control....

Thanks for the help -- I'll practice on some scraps....several scraps!
Philip

Anyone else with any advice?
Philip

I just did it ! Make a negative of your window. (A frame it will just fit it). I did mine with a jig saw and fine tuned it with my belt sander. You only get 1 shot at the wall but you can remake the guide if needed.
Screw it to your sides inside the trailer. Use a flush cutting bit with a bearing end. Drill a starter hole large enough to put bit thru and just let the bearing follow the guide. It's a lot more work but both cuts will be identical. A good bit will be a $ 25 - $30 dollar investment but it will cut the 3/4 in one pass just feed it slow and let the bit do the work. Work clockwise and with just a little side pressure the bit should not wander from the guide.

Well..... I just did one side using a jigsaw and "easy does it".... once I get the door trim on there I think it'll be fine.
Philip

Creamcracker wrote:Well..... I just did one side using a jigsaw and "easy does it".... once I get the door trim on there I think it'll be fine.
Philip

Scary...Huh!?

Philip...one more scary thought...the thickness of the cut will not be enough to put trim on and shut the door...you will need around a 1/4" gap all around the door to accept trim and have room for the door to shut....
madjack

madjack wrote:Philip...one more scary thought...the thickness of the cut will not be enough to put trim on and shut the door...you will need around a 1/4" gap all around the door to accept trim and have room for the door to shut....
madjack

Yeah -- I got that taken care of with the table saw and lots of sanding - thanks mj.
Philip