Hard Lessons Learned
I'm collecting all of the lessons that I've learned and
putting them here. Kind of a knowledge base for those of
us who have large, gaping holes in ourcarpentry knowledge.
- Inside Curves -- Cutting curves on the
outside with a jigsaw is substantially easier than
cutting a curve on the inside with a jigsaw. The
solution? You an appropriately sized hole saw (a saw
like drill bit used frequently when installing door
knobs and locks) to get the curve just right. Then
you can use the jigsaw to cut the straight lines.
- Straight Lines -- If you're like me,
cutting a straight line is not an easy task in and of
itself. The recommendation that I got from a co-worker
of mine, Norman, was to clamp a 1 x 2 down to the
surface and use it a cutting guide. Thanks, Norman!
- Cutting -- Cutting is a pain. It chips. It
tears easily. Life is simply no fun with it. If you're
going to use a jigsaw, get a blade where the teeth
point down, not up. Using masking tape over where you
are cutting helps reduce chipping. If you can clamp it
to another board before cutting, that will help
immensely. My neighbor, Ron, and several carpentars I
talked to suggested using a router to cut the formica.
Being that I don't have a router, I went to the next
best thing, suggested by Josh, and that was to break
out the Dremel tool with a cutting bit and go town.
|This hole was drilled with a standard drill bit. Note the chipping of the formica around the hole.
Drilling -- I found that regular drill bits
chip the formica like nobody's business, but paddle
bits make nice work of it and don't chip.
|This hole was drilled with a paddle drill bit. You can easily see how much more clean the edge is.
- Attaching -- I've heard two ways of doing
it. You could be a router blade to cut the notch or
you could use a utility knife and cut off the hook
- Speaker and Fan Grills -- I searched and
searched and searched. David suggested that I use
attic vents, but I couldn't find any in 2.5". I could
only find them in 3", 2" and 1.5". But then I was in
Radio Shack and found some 2 Piezo speakers.
The speakers are help to the grill by to plastic
rivets. Drill out the rivets, pop the speakers out.
The only gotcha is that you have to glue the mesh to
the plastic frame as it's normally held in place by
the speaker itself. Cost of one of these? $2.67 at
your local Radio Shack.