Routing out a recess .... HELP! ... a bit beyond me! ....

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Hi

Have taken on the challenge of fitting a No-Ha invisible door opening mechanism. Got 90% of the way there, but the last hurdle is to rout out a 40mm x 16mm deep recess, leaving 4mm either side of the door face.

Hopefully the attached pic will make this clear.

I have routed out the initial big opening (45mm x 87mm) ... but have no idea what kind of router bit to order so that I can gouge out 16mm of wood (just leaving 4mm untouched!). The handle manufacturers suggest buying one of their 'specialist' tool bits ... but they are asking 200 euros for it! For a one off door that is crazy, so I was thinking maybe one of you geniuses may be able to help me ... THANKS!

 
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Bu**er!!

Sorry - just looked at the picture again - I have removed my ramblings, because they did not address your problem!!
 
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Hey thanks ... well ... this is as far as I've got - see attached image.

Yep - doesn't matter about the rounded corners.

The weird thing is, there is a big ironmongery outfit who sell a LOT of these hinges in the UK, and apparently they don't bother stocking the very expensive 44mm router bit because no chippy ever asks for it! So the guys out there must be finding some workaround that I haven't yet thought of.

I was toying with the idea of just simply cutting a 16mm enlargement to the hole, and then laying/rebating in a 4mm bit of ply back over the top and then do my best to make the resulting 'joins' as invisible as possible ... but I think that would be a bit of a bodge!

Anyone care to post a link to a rebate cutter that might do the job? I'm all a bit lost ... thanks ...

 
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Okay - I've never seen one of these before and I'm not quite sure what you're up to but...

Can't you just drill in from the edge of the door? Isn't this section just the end of the deep mortice for the lock which has been expose by your beautiful routing? Maybe I'm missing something...

Edit: I've studied at the pictures again - you want to remove the wood inside the ply, right? Could you use a biscuit cutter? You wouldn't need the bearing 'cos you'd be using the top side of the bit. Set the top side to be 4mm below the sole plate of the router and route up to the shank of the bit. That should shift most of it... I guess that you'll need a cutter over 38mm in diameter (for a 1/4" shaft) to clear 16mm or you'll need to finish it off with a chisel through the edge of the door.
 
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Thanks 82 ... and yes, not possible to come in from the edge.

A biscuit router may well be the answer, but it does depend on it being able gouge back 16.5mm into the door ... and start at a depth 4mm down and go a further 10mm. Would that mean I need a 33mm diameter cutter?

Might have to go and buy a cheap bit from Screwfix and experiment on some scrap ...
 
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THANK YOU!!

Yes .... result! .... a £4.99 biscuit router bit from ScrewFix did the job perfectly ... albeit I had to do it in two passes, and squeeze the last 2mm out in bodgelike fashion with a drill bit.

But thanks again ... great to have knocked it on the head!
 

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