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I would not necessarily make it larger but you will be using a jigsaw or recip saw and they are not like using a scalpel either. I have a template for both sizes and use it. Would be a huge pain in the azz to try make it bigger later so I would make a template and use a pencil and draw the boot on a piece of scrap wood. Cut the template the EXACT size of the boot. Then use a sharpie marker with the template and the thickness of the sharpie should give you enough room to slide it in.
 

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Discussion Starter · #6 ·
ok, i have one in. i made the hole just slightly larger. ugly hole. i carefully made lines on the floor, but with all of the sawdust, i could not see well enough and went off some.
oh-well, is what it is.
 

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To make holes not so ugly use Bosch saber saw blades in conjunction with masking tape to prevent tear out. A vac or small fan takes care of the dust very well. Before you know it you'll look like a pro and someone will want to hire you.
 

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Good point. Masking tape works well.

I cut hordes of them back in the 80"s when we were ripping out lots of octopus gravity oil fired furnaces and installing complete ductwork jobs with new furnaces.
 

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