You can overcome the bearing problem by using a router template guide, they fit onto the base of the router, this will let you use a standard straight cutter and by adjusting the router depth you can take smaller cuts which should give you better control. You would need to alter the pattern and make it oversize to account for the guide
Yes, that's what I'm now doing, well, with a jigsaw anyway. The reason for using the router for the initial through hole was simply because a routed hole would be precise.
You have already picked your strategy so this is not uber helpful but: 1) there is a vender of portlights that accommodates thick hulls and 2) yes the jig saw is the weapon of choice. Good luck.
Yeah, price had more to do with the choice of portholes than anything. Not that they don't make them for thick hulls, I just didn't want to spend over a grand on each one. The jig saw, while not leaving perfect holes, is most certainly the easiest way to go.
You can overcome the bearing problem by using a router template guide, they fit onto the base of the router, this will let you use a standard straight cutter and by adjusting the router depth you can take smaller cuts which should give you better control. You would need to alter the pattern and make it oversize to account for the guide
I looked at one of those today, thought about it, then decided against it. Maybe should have picked it up...
Would like to see the thickness of the hull to see how well it bonded
Why dont you Cut Out the inner field of the porthole Prior to Routing with a hacksaw?
Yes, that's what I'm now doing, well, with a jigsaw anyway. The reason for using the router for the initial through hole was simply because a routed hole would be precise.
You have already picked your strategy so this is not uber helpful but: 1) there is a vender of portlights that accommodates thick hulls and 2) yes the jig saw is the weapon of choice. Good luck.
Yeah, price had more to do with the choice of portholes than anything. Not that they don't make them for thick hulls, I just didn't want to spend over a grand on each one. The jig saw, while not leaving perfect holes, is most certainly the easiest way to go.