I have a finished piece of furniture that I need to cut a rectangular access door into and I would like to hinge the piece I cut out. The size would be roughly 4" x 6" for the access. I need to cut 4, very thin cuts through the wood face to make the rectangle, and add small hinges for it to open. The face of the wood is perpendicular to the floor and the furniture can not be moved, so it needs to be cut in place.
Submitted by DWehr
Answer:The best way to do this is with a jigsaw. I've done this in the past and found that a metal cutting blade works best. It has extremely fine teeth, and provides a narrower kerf than woodcutting blades. Since you'll be using the cut out as a door, the narrow kerf is important. You'll need to cut very slowly, but the better quality cut is worth it. If your jigsaw provides an orbital action, don't use it.
Carefully lay out the door. You'll need to start the cut on each of the four sides by rocking the running blade into the material. Do this gently. I find that rocking down and moving forward slightly at the same time is the easiest way to penetrate the stock. Practice on waste wood. Cut to the inside corners, then repeat the process for each of the other sides.
Once you've got the door cut out, you can add the hinges of your choice.
George
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Lots of information here in the comments. Some things I might not have thought of. I learned something today!
George, why not use a multitool? Kerf is thinner and easier to penetrate the wood and maneuver.
Cut the sides first. Secure cutout with Tape on all 4 sides. then cut Corners.
I’m no expert by any means, but would an oscillating saw work for this?
For cutting a small access door, I would use an oscillating multi-tool — it produces a thinner kerf and provides a cleaner insertion than rocking a jigsaw into the cut.
Another approach is to use a Dremel. I've never succeeded with dropping a blade into wood. Too much bouncing and risk of damage to surrounding areas. Challenges like this are also how I justify adding a tool to my shop.
With a door that small it will bind as the hinge swings it open (even full-sized room doors have or should have a beveled edge). I would suggest either setting the blade at a 5-degree bevel on the edge opposite of the hinges, or cutting the door with square edges and planing a bevel on the edge opposite of the hinges. I also agree with the previous comments that an oscillating multi-tool would be a better saw to use.
Methods to cut a through mortise in end grain 2x4. 1/2” x 3 1/2 w x 3 1/2 deep.
I lay out the cut lines then cut out (similar-size) door openings using a half-circle metal blade on my Dewalt Cordless Oscillating Multi-tool. I do not cut all the way to the corner with the half-circle blade. I then place hinges over where they will be mounted and use painter's tape to hold things together. I make painter-tape tab(s) to grab and tape it to the center of the cutout. I make the final cut with a fine-toothed Japanese flush-cut saw.
For cutting that small opening and using it as the door. I have found an oscillating.saw works well.. The narrow blade cut helps keep the cut straight by letting the blade follow in the kerf.