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What is the best tool to make this type of cut? T

1K views 8 replies 9 participants last post by  AndyJ1s 
#1 · (Edited by Moderator)
There appears to be small circles in each corner. This is to make plyometrics box for working out.
 
#3 ·
Not sure if you meant to post a picture but that may help. The only holes I can think of in a plyometric box would be hand holes on the sides to grab it. If you're in a hurry and doing it on the cheap, a 4" hole saw hooked up to a drill would put circular holes in the box. A jig saw or oscillating saw would work to cut out the wast between two smaller holes and make a more elongated slot. A router with a pattern bit and a jig to guide it would be the more "professional" approach, but would require a router and considerably more set up time making the pattern/jig. There's a couple ways to skin this cat.

Not sure if that is what you're talking about but hope it helps.
 
#7 ·
Agree with the other posters in that a pic would be greatly helpful. However your post makes me think of a friend of mine that makes plyo boxes for gyms in bulk. He uses a design very similar to the one John Smith posted, but since he makes a lot of them he outsourced the panel production to a guy with a CNC machine. The CNC machine has a very specific bit size which results in the corners for the tab cutouts having a small circular shape. The CNC machine won't do a 90 degree inside corner because the bit is circular.
 
#9 · (Edited by Moderator)
The holes, and cutout between, them could also be cut with a mortising bit of the desired diameter, with a plunge router, preferably on a router table. You would need to cut a smaller slot with a plunge cutting (center cutting) bit to clear the non-cutting center of most mortising bits. A jig built to locate the stock and limit the cut would help a lot if you are making several of these boxes.
 
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