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Old 04-09-2012, 09:08 AM   #16
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Cutting Opening in Hollow-Core Doors


Cutting the doors with a router is the way to go for that many doors.

But I still think you should consider a slightly different approach to the trimming of the plexiglass.

The filler blocks you mentioned are fine. But when it comes to the stops for the glass, you could make up some outside corner molding that creates a stop for the glass and reaches over the skin of the door to cover the cut line through the door and the edge grain of the skin.

You can play with the proportions of the molding to suit your needs and see what looks best to your eye.

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Old 04-09-2012, 11:26 PM   #17
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Cutting Opening in Hollow-Core Doors


yep^^^^^ or do it in 2 pieces a stop piece then a trim piece
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Old 04-13-2012, 03:21 PM   #18
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Cutting Opening in Hollow-Core Doors


A router sounds fine, but maybe a little bulky. How about a laminate trimmer or roto-zip?
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Old 04-18-2012, 01:19 PM   #19
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Cutting Opening in Hollow-Core Doors


Quote:
Originally Posted by 8888 View Post
The opening will replaced with a plexiglass panel.....there are 12+ doors
I can offer not much advice as to how to cut the voids in the doors.

BUT I gots to know.

Why are you cutting 12 doors and installing plexiglass in the voids??
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Old 04-18-2012, 01:40 PM   #20
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Cutting Opening in Hollow-Core Doors


Tape the area to be cut with masking tape to help control any splintering. Not sure I understand how you are going to deal with this looking decent given the cardboard interior of the door either. You might see if you can find a stock marine window with trim or something?

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