Quote:
Originally Posted by RRaider
Ok, this is 3/4" plywood, so I assume I will need a very stout router (2hp+) and will need to take it slow, perhaps only going 1/4" or so per pass....
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You don't need a big router
If you have a plunge router, you can likely cut the whole panel out in one pass using the template & guide bushing (or bearing bit) method as indicated above.
That said, if you are not familiar with using a router with templates, then you will spend more time making the template and messing around than it is worth.
As I mentioned, I would rough cut the hole out within 1/8" or so of the finished line using a jig-saw. I would then clamp (or use double sided tape) a straightedge to the panel and use it is a guide. The quickgrip clamps are great for this. Use one straight edge as a guide and another as a STOP so that you don't route too far.
Do you have a router? Are you borrowing or buying?