Precision cut in a restricted space?

[NeilPalfreyman]

I'm adding some shelves to a pair of existing cabinets and I need to be able to cut some 16mm slots 75mm back into a pair of supporting uprights to take the new shelves (they're CD/video cabinets, in case you were wondering.)

My problem is that I have a *lot* of these cuts to make, I want the job to be neat an quick if possible, but I only have 130mm clearance either side of the uprights, so a router is out of the question (at least my router is!)

The uprights are securely glued in place so removing them isn't an option either.

I have a multi-tool but don't think the cut will be neat enough and a Jigsaw at right angles to the upright wont cut deep enough.

Any suggestions?

 

[foxhole]

Butt join and glue?

 

[NeilPalfreyman]

...may have been a better option in retrospect but I have already had all of the shelves cut to size assuming that I'll slot them. Doh.

I'm considering getting a Dremel DSM20 to do it. I think this would make it a breeze as I could make a set of jigs to get the shelves at the right height, but I'm hesitant as I cannot be sure if there will be enough clearance to get the Dremmel far enough in for a 75mm deep slot.

 

[big-all]

i would say forget it
get them cut exact length
make up a jig with 2/3 or4 x5mm holes in it
and use these
http://www.screwfix.com/p/steel-she...nd Fasteners&gclid=CM_e3Nm718ICFSYIwwodpAYALA

or these
http://www.toolstation.com/shop/p32449

 

[Burnerman]

I think you've given yourself a bit of a headache there Neil....how about those metal dowels that you find holding shelves up in kitchen cabinets?
I guess you could get in with a right angle drive drill, and they will be strong enough.
It will mean having your shelves remachined though.
John

 

[NeilPalfreyman]

Anything involving drilling is pretty much out of the question, again due to the lack of clearance which is only 130mm.

Have just been out to B&Q to size up a Dremel. It would certainly fit and give me more than enough cut depth and I could use a jig.

However I have been reading that, as it's an abrasive rather than a "normal" blade, it gets expensive having to use proprietary blades.

I need to make about 240 75mm cuts in total!

 

[big-all]

have you got a picture or 2 please

if my mind is correct you would take several weeks as each slot will take several passes if the blade is say 2mm and the slot 15mm then thats a minimum say 10 passes if using a guide or jig having to clap and move between passes

also iff its chipboard core the blade will give up after a few metres
have you thought about an angle drill and those shelf supports possibly with a cut down drill bit

 

[NeilPalfreyman]

Will stick some photos up soon - just need to re-charge my camera 'cos the room the cabinet is in is dark so I'll need a flash!

 

[Burnerman]

240 cuts
Neil, you'll want to do yourself in before you've done a quarter of that....
Big-alls idea of using a cut down twist drill in an angle drive should save your sanity!
John

 

[cajar]

I wouldn't want to do 1 x 75mm cut with a dremel let alone 240 of them!