Fixing an oversized hole in mdf

[@if]

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

I've attached a couple of pics to help show what I've done.

What I would like to do is to some how resize/mould the hole so the terminal fits well. The current oversized hole only allows two screws to be used and if the fix can allow the use of more then that would be great - but the primary result is to get a good tight fit.

I have to hand pva glue and pollyfilla and also some mdf off cuts - but I think a plug may be out of the question due to the odd size and fit required.

 

[carlb40]

I would use the jig to make a bigger hole, but with a lip on it. So rout the hole half the depth of the mdf. Make a matching disc again rebated half the depth of the mdf. Glue the disc in place. When dry, rout a new hole.

 

[@if]

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

 

[Phil Pascoe]

You mention polyfilla - there isn't any job you can imagine that there isn't something better for.

 

[GazPal]

You could also consider using a hole saw for this type of fitting

http://www.axminster.co.uk/axminster-ax ... rod818151/

 

[@if]

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 "just in case" for the future - although looking back at how I drew the cutting circle in the first place and then how I cut it, I have now leared two lessons. One of them being the all important "measure twice, cut once!"

 

[GazPal]

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 "just in case" for the future - although looking back at how I drew the cutting circle in the first place and then how I cut it, I have now leared two lessons. One of them being the all important "measure twice, cut once!"

Make an MDF plug for the hole and glue it in place if you need to centre a jig on the hole. The simplest method would be to square the hole off with your router and glue a square plug in place, using the same rebate method Carl suggested. You can then re-route your circle or use a hole saw. The extra time taken to get the repair right will pay dividends in terms of end results.

 

[Losos]

I have to hand pva glue and pollyfilla

Aaaaaaaaaaaarghhhhh no not pollyfilla pleeeeeeeeease :lol:

 

[@if]

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

 

[Giff]

If you are going to paint it when finished 2 pack filler like Ronseal http://www.screwfix.com/p/ronseal-high- ... 550g/45077 will completly fill the hole and you can then re-drill it. If it is a deep hole you may have to build it up in a couple of goes and sand it dead flat.....

 

[@if]

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 )