Head cab control access cut

[Sonny ReVerb]

Hey all,
I'm working on a head cab for a square chassis (no slant front). Looking for woodworking tips on how to make the cut for access to the control knobs. I'm thinking router with a template...?

[jjasilli]

Yes to a router, to finish the job.  But a cut that deep should first be cut with a saw to within 1/8" - 1/16" of the outside of the Line; then router. I think I would then use a flush trim or pattern bit with a template; then a roundover bit.

[Sonny ReVerb]

Thanks, that worked pretty well. I made the initial cut with a Sabre saw.

[Sonny ReVerb]

Then I made a template for the router to clean it up. I actually made half a template. That way I can flip it over to do the other side and it will work for any width cab.

Of course, my fine HF router decided to self destruct at that moment (you get what you pay for). I took it apart and the hard plastic cord keeper inside was in about five pieces and the cord had pulled loose from a connector. I made a new one from a small piece of thin plywood, reconnected the wire to the connector, and she's back in action.

[Sonny ReVerb]

Looking good, so far. I think I'll break out the round over bit tomorrow...

[jjasilli]

 

[Sonny ReVerb]

Had a chance to tolex the cab yesterday. The control access cutout is not an easy shape to cover with tolex.

[sluckey]

Looks good.

[jjasilli]

Well done!  You're approach is fine.