Fishingtomatoseed wrote:Dan,
What was your process of cutting the door out?
I was going to skip over that, since it did not go anything like I had planned. But since you asked I guess I will share.
I cut the door out of my side profile template. I then clamped the template to the wall. I used a router with a bit holder that holds 1/8" rotozip cutting bits. This is also how I cut the ledge along the top of my walls where the spars will set. I made multiple passes about 1/8" deep until I got all the way throught the thickness of the wall. It worked fairly well for cutting out the ledge, so I thought it would be ok for the door.
Well it did not go so well, not sure what was going wrong. The router bit wanted to keep drifting and the cut was pretty sloppy. I also broke all 4 bits that I had. After I broke the last bit I gave up on that process. I then decided to finishing cutting out the door with a jigsaw and clean up the edges with a belt sander.
I cut the dook out the rest of the way with the jigsaw. I thought all was ok until I removed the door and realized that the blade had drifted almost 3/16 of an inch is some spots. Note to self: DO NOT USE CHEAP JIGSAW BLADE FOR SOMETHING THIS IMPORTANT!!!!
To fix this I used bondo with fiberglass fibers to build up the areas on the door and the cutout. I then used a straight edge and router edge trim bit to trim the edges. On the curved part I just used a belt sander. I will also put fiberglass and epoxy over the edges.
Dan