Looking for a Suitable Tool

I have an MDF timber box (describing it simply) that has a 200mm. hole cut out the bottom..The bottom panel thickness is 25mm.

I want to increase the hole to 250mm. in diam. The internal box base is approx. 300x300.The depth of the box is 150mm..

Normally a simple enough job, but in this instance I can only reach the hole by going into the box because it's a part of a larger construction..

There's not enough room inside the box to use a router or jigsaw, so any ideas what sort of cutting tool I can use..

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Brad

Coping saw is the first thing that comes to mind.
Mostly used with holes drilled around the shape you want cut out, then cut between the holes and clean up the cog shaped hole it leaves with a file or a power burr.

Prof

Sorry..one thing I forgot to mention..There is another solid panel directly below the cut out, and the space between the panel that has the 200mm. hole and the solid panel is only 50mm.. so there's no room to fit a coping saw..
It can only be cut from inside the box like you would normally use a router or jigsaw..

Jason

In addition to @Brad, some of our other keen woodworkers on Workshop include @darylhewston, @AndrewJones, @Wayne, @She_Skills and @Rusty-Saw.

Hopefully they will have some suggestions for you @Prof.

Jason

darylhewston

@Prof

What about a reciprocating saw or multi-tool with a timber attachment? Otherwise you could try a handsaw cutting multiple cuts from the 200 to the 250 mark and knocking out with a hammer. Tidy the larger hole with sandpaper.

Cheers

Daryl

AndrewJones

Can you provide a photo? Might help with how to approach the problem.

Prof

Thanks Daryl..
A reciprocating saw might be the answer if I can get a blade that's less than 50mm. long..
Don't those multi-tool devices only have broad flat cutter? would it cut through 25mm. thick MDF?

Prof

This is the unit in question..The dark angle brackets are only there for support during construction..

Wayne

I think looking at your drawings the only option would be a Mutli-tool, different width blades are available and it would chew through MDF like butter. Not really designed to travel but a series of individual cuts will conquer the task quickly.

Brad

https://www.bunnings.com.au/dremel-multipurpose-cutting-kit_p6373718

Should fit in with room to spare, from memory it is painfuly slow though.

Prof

Thanks Wayne...

I'm glad to hear that the multi-tools will cut through the MDF very easily..

There is a fairly narrow blade that comes with the kits which should do the job..It will be just a matter of making a lot of cuts and finishing off with sandpaper..

Prof

Thanks Brad...

Yeah I've use those bits before and they are not very effective

Rusty-Saw

Can you get a hole saw on a power drill in there, if you can you will need to secure a scrap piece of wood onto the face and using the hole saw cut into that and continue through into the MDF, once done remove the scrap and you now have a neat round hole, sand to smooth, done. You need the scrap as a guide for the hole saw as you can not use it to expand an existing hole.

Prof

Are there hole saws 250mm. in diam.!?

Rusty-Saw

250mm is a big hole saw, if they do it would be expensive, sorry I must have misread the size you are trying to work with.

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