How difficult would it be?...

Joined
23 Dec 2002
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Glasgow
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To install a porthole window into a door? A rectangular one already exists and I was thinking of upgrading.
 
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Not too difficult with a router. If you route the hole from the outside of the door leaving a rebate for the glass you could then pin and putty your glass in place from the outside.

You would need to rig a template to run the router off to ensure that your circle was true but that shouldn’t be too difficult. A flat board pinned to the underside of the door, a spacer piece (which would sit in the rectangular hole of the old window) and a “compass” template to attach your router base to.

You could also run the router around the circular opening once it’s cut. If you used an ogee bearing guided bit it would give you a nice decorative bead around the window. And you could do this on both sides so that it looks good from the inside as well.
 

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