Duh moment take 2

[LarryG]

you can make the hole from the outside, bcakside of the box.
Unless he has more permanently attached stuff there.

Aye, that's the rub. The bottom panel visible in this thread extends beyond the router compartment on the same level, so the problem is the same from both sides. See the "Weekend 4" pics in Jon's BT Mobile Base Diary thread, toward the bottom.

[poolhound]

I'm thinking the real problem here is that Jon wants the hole in the back panel to be hard against the bottom panel of the compartment -- otherwise it's going to fill up with dust up to the bottom of the hole. That means the cutter (and the tool driving it) is going to run out of working room for roughly the bottom half of the hole.

I can think of a few ways to sorta-kinda get it done. None of them are pretty.

Larry, you got it. I have tried to mark up the picture so you can see where the inside hole needs to be and where the pipe would run to and the DC connection is intended to go.

Cutting into that outside panel shouldnt be too hard, its that inside corner that looks like it will be a pain. I was going to run out to HF today and pick up one of those RA drill attachments and see if that will work with a hole cutter.

The other option will to cut a really rough hole on the inside that I can the attach a secondary piece over that has a clean hole already predrilled in.

[LarryG]

OH! I took "back panel" to mean the one directly in front of the camera lens, placing the hole 90deg from where you've shown it. That would be the "back panel" in a NYW-style router station. But you mean "back" as you face the front, long side of the mobile base.

I'm now thinking you might be able to cut the "inner" opening with a hole saw and an arbor extension. The trick may be finding a hole saw of a diameter that will match the OD of your pipe or fitting. You may have to cut the next larger size, and seal around the pipe/fitting somehow.

[poolhound]

OH! I took "back panel" to mean the one directly in front of the camera lens, placing the hole 90deg from where you've shown it. That would be the "back panel" in a NYW-style router station. But you mean "back" as you face the front, long side of the mobile base.

I'm now thinking you might be able to cut the "inner" opening with a hole saw and an arbor extension. The trick may be finding a hole saw of a diameter that will match the OD of your pipe or fitting. You may have to cut the next larger size, and seal around the pipe/fitting somehow.

Sorry for the confusion. I was only planning on using 2 1/2" so I think I may have a hole saw that will work.

[JetDoc]

How about getting a drill extension. Cut your hole through the back panel. Then attach the extension (i've seen them up to 18") and drill the inner hole from the outside. You can place the hole saw inside and use it to mark the center and drill a pilot hole to guide you from the outside. I hope this makes sense.