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I've posted a pic of it here: fixing-an-oversized-hole-in-mdf-t69593.html

We've just had an offer accepted on our first house and although it is good enough to move in, I intend to do as much as I can once we do from drawers/cupboards and working my way to a kitchen! (I told my mum and she laughed at me :o) There is a decent sized brick-build shed with power that I...

The box is finished now - I used a holesaw larger than the botched hole. I used some walnut veneer with finshing oil and clear wax to finish off the box. (Spot the many mistakes! #-o )

Just to update - I used a combination of edge trimming (which was easier than I thought) and sanding. The end result was acceptable :)

Ended up going down the holesaw and bigger terminal router as I was a little unsure how long the router replacment would take. Thanks for the suggestions as I'm sure they will come in use in the future :)

Thanks Chris - although the problem was more to do with power than speed. I've logged a return notification with the vendor.

Looks like it - very annoying as I had one more cut to do! :(

I used the router without any issues yesterday, however this morning has not been so good. The first problem was it seemed the like power for the router was shorting out - it was slowing down/stopping and starting again, and this was whilst not actually cutting. I also think I smelt some...

I was planning how to carry out Carl's suggestion and it occured to me that I would not be able to cut a larger hole on the box iteself with the jig, as I won't be able to "center" it. I think I'll give the pollyfilla a go and see what results I get. I might just get a set of hole saw as a...

Ahh - very cunning! I'll give it a try tomorrow.

will do :)

So I routed out the larger sized holes needed for my subwoofer with a jig, without any issues. But I also needed to do a smaller sized hole to fit in the speaker cable connectors. I decided to do this by hand but what resulted was far from a circles and too big :oops: I've attached a couple of...

I've been using it today to cut out some circles and also do some slight size adjustments on one of the mdf panels......and I have to say once I got past the initial "nerves" I found it a joy to use! Not of the the stickyness that I had when just playing about - so all good :) As an added bonus...

I'll try my first cut tomorrow and will see how it goes. The rack/pinion wheel are alot smooter - so I could use a combination of taking it down with the plung and then using the wheel to get to the pre-set depth.

So I got my new router today (thank you Ironmongery Online) and have been playing about with it and have noticed the plunge is not smooth at all when plunging at a reasonable pace. It actually gets stuck unless I plunge at a fast(ish) pace - which I don't think is normal. Having looked on this...

Thank you

I've viewed some video's on youtube and can't figure out where the bearing would sit to bring the lips level with the back piece. *edit* just saw the steve maxwell video and I think I now understand. Will order now

I'll do it tonight, but I've uploaded one from a popular forum. Mine isn't as pronounced as the pic - but it looks like the trimming bit is the way to go :) I'd like to keep all the edges straight so the veneering is a little easier.

Thank for the suggestions. The cutter (TS1418.5M) is without any bearings (judging by the pic, I'll check at home later). I can see how the trimming bit will help where two pieces meet and there is a straight for lip to trimm off - but I also some a little issue where the side panel joins up...

As you've probably guessed by the subject heading - I'm a noob! :P I'm in the process of making a subwoofer out of 25mm mdf. Most of the carcass is ready, however the sides have not all joined up as evenly as I had hoped. This means I have some slight lips/overlaps. I will be veneering the box...