Need to enlarge wood console opening, any suggestions on cutting wood?

[spinedoc]

I'm retrofitting a double din radio to fit in my SL. I've already modified the support brackets and relocated all the switches underneath the single din.

The last thing I need to do is enlarge the single din opening to 4 1/8" high. Yeah I wish I had access to a laser cutter, or a CNC, but I don't.

Anyone have any suggestions on actually cutting the wood? I'd like to make them as clean as possible, but will accept some roughness as there will be a bezel over it. I'm not sure if a jigsaw with a fine reverse blade will do the trick neatly.

Any suggestions?

[StaggerLee]

With an exacto knife, scribe your line deep enough to go through the clear finish on the wood . Then get a hand scroll saw with a fine tooth blade. Make sure the teeth make contact with the finished side of the wood first on the cut stroke so any splintering that may occur will be on the back side. If the blade is the other way, it will separate the clear coat and splinter the wood.

If you take your time, it will look like you used a laser.

[DanielG]

maybe look into a Dremel with a router bit?

http://www.dremel.com/en-US

[RickM]

A Dremel router would probably work very well.

Another approach would be to use a veneer saw. Be careful to always keep the entire blade on the surface you're cutting. If cut with a saw in the conventional manner then you have a better chance of snagging a piece of wood and causing damage. Some use masking tape on the line to be cut to further limit damage.

[Winsteadi]

I am told that this is a no-no - drops value of car big time.

[RickM]

Originally Posted by Winsteadi

I am told that this is a no-no - drops value of car big time.

Must say I agree. If it were my car I'd source a used piece and play with that. Then you can go back to original if selling.

Just a thought.

[spinedoc]

Thanks for the responses guys. I used a regular powered handheld jigsaw with a reverse cut blade. I taped off the console to protect the finish. It came out great. Now I have to adapt a bezel to look flush.

I'll post some pics when I'm done, I've got a Pioneer Avic D3 going in. By the way I am not chopping up my console, that's safely wrapped and stored. I bought one off ebay for $150 that's getting chopped up. The switches were all either relocated to the bottom of the console, or inside the dashboard glove compartment, it came out very nice.

[rkasal]

Before any cutting or drilling of fragile wood or laminates like this, you may want to put masking tape over the area to be cut. You can use the painter's kind as it won't leave a residue.

And, using the tape, you can make your marks for cutting. Just be certain blades/bits are sharp.

Randy Kasal

[iwrock]

Pictures?


A friend got a D3 put into his F350. I gotta say its a nice unit, as it does/plays just about everything.