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Permalink Reply by Dan Sleep on January 17, 2010 at 9:07am

I had the same question. Using the templates to draw them is fine, it is the cutting out that I have a problem with. I tried a test with the Dremel tool once, but I couldn't get them nice and smooth.

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Permalink Reply by Andy on January 17, 2010 at 2:20pm

There are the special bits for cutting dry wall with a dremel tool let me go to the web to see if i can find the name. I think they are meant to cut on sides. A guide would be a good way to go with something like this.

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Permalink Reply by Diane in Chicago on January 17, 2010 at 2:51pm

Here's the link to cool templates:

http://www.scalelength.com/catalog/index.php?main_page=index&cP...

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Permalink Reply by Diane in Chicago on January 17, 2010 at 2:51pm

I believe the Cajun cuts his with a hand held scroll saw, yep. Nice and slow is apparently the secret.

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Permalink Reply by Wade on January 17, 2010 at 3:55pm

I drill a hole at each end to get things started. Place some masking tape on the area will cut down on splintering and tearing out.

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Permalink Reply by Michael Gajeski on January 17, 2010 at 8:44pm

On my first cbg, I made the f holes by drilling holes at either end and then using a hack saw blade to cut out material between the 2 holes. then I used a file to clean things up. It only took about 30 minutes for each f hole. It turned out pretty well, just took a little patience.

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Permalink Reply by Tim Fleischer on January 18, 2010 at 5:04am

I used a dremel cutting bit for this one. You need to take it slow, have a good grip on the dremel and make sure the box (or lid) is secured somehow.

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Permalink Reply by Zack Burke on January 18, 2010 at 7:00am

What I did for mine, and it was a big pain, first I drafted my design onto graph paper with my box dimensioned out around it and copied the design to my box.
Now from that point, for each sound hole bore out 3 large diameter holes with a drill press (or power drill) Say with about 1/2" Diameter bit. Place the first two holes at either end of the F shape where you often see the round ends, then also place a hole in between the two ends where the diamond shape usually is on an F shape sound hole. You may want to make this hole slightly smaller considering your design, say 3/8" or less (again depending on your design).

Then I take a small bit, about 1/4" and bore out the area of the sound hole that spans between the first 3 holes. Finally I take a coping saw blade (frame removed) sand paper and a triangle file and clean and shape the sound hole to its final shape.

Its a pain to explain but it doesn't really take too long and you get great results.

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Permalink Reply by Tim on January 18, 2010 at 7:06am

i use a combo of dremel, coping saw, and files.

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Permalink Reply by Nathan King on January 18, 2010 at 9:35am

I use a RotoZip to cut away the majority of the wood, then clean it up with a variety of files, then sandpaper. I believe they make a RotoZip like bit for a dremel... but I will say you gotta have a steady hand. The roto can be squirrely at times, but it sure makes quick work of the wood!

And with paper covered boxes it's not really a concern, but with the wooden ones I'll use some painters tape to help prevent chipping.

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Permalink Reply by Nick on January 18, 2010 at 12:49pm

i just use a drill for each of the holes, and then just a plain old pocket knife.
in terms of templates, i don't use em. i draw out the two holes with a ruler on each side, then i draw a line connecting each set of points and sketch out the rest.

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Permalink Reply by THENUGE on January 18, 2010 at 3:15pm

i ended up just using the coping saw...wasn't too bad i just feel like i need an extra hand putting the blade back in after feeding it thru the box

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