Teardrops n Tiny Travel Trailers

Hi all,

I wrongly put my question in the build journal. - its had many views and no replies.

I cut a template out from a Kit profile I ordered online. -

I"m using pre made doors though, and I want to get the template right before I use a flush trim router to cut the pattern onto the good (expensive) plywood.

So, I'm really not happy with my first cut out on the door especially on the corners( I used a jigsaw ) , and I am really glad I am doing some testing templates on the crap plywood.

Does anyone have any tips on cutting the corners for the door cut out? the corner of these doors is actually a little proud of the straight area - when they bent the curves in the factory it pushed the curve out a little proud

And since these doors don't have an internal trim ring to hide any of my unscrupulous work........Id like to get it right.

I'm thinking of a tracksaw or circular saw with guide rail, for the straights, and maybe a router with a circle jig? ( cutting out the circles before the straights obviously )

What does everyone else use to cut the corners?

Any advice greatly appreciated.

The norm would be to make a template out of 1/4” ply and use either a router bit with a top bearing or a spiral upcut bit with a guide bushing. If you close the latter keep the cuts limited to about a 1/4” depth.

T


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Thanks Tony,

I had not considered a separate template from the template, I'll use a compass to draw the arc, and maybe a router table to cut the template.

powelly78 wrote:...............

I'm thinking of a tracksaw or circular saw with guide rail, for the straights, and maybe a router with a circle jig? ( cutting out the circles before the straights obviously )

That's what I did with mine. Still have to clean it up with sanding. (I was not trying to save the cut out for the door.)