parkham

I have been cutting some holes in some of my sailplanes fuses and tailfeathers to lighten them up is there a better way than using a compass to mark it out then using an xacto knife do hole saws work with balsa sheet without ripping it

RDJeff

My Feedback: (11)

I've used a couple of techniques for this. Depending on the size of the hole needed, you can use sharpened tubing of whatever size you need, sharpened properly it'll cut right through it. PVC or ABS pipe or fittings can get you a lot of different sized holes. I've even used tin cans sharped to cut holes for retracts. Another tool I use is a circle cutter from X-Acto, kind of like a compass, but with a blade. It'll do up to a 6" diameter hole. It works fairly well, but you have to pay close attention to what it's doing or it'll wander on you. Hole saws typically have pretty coarse teeth, and would give you a pretty ragged hole.

parkham

thanks typically the holes I need range from 1/2 in up to 2in I made a compass with an xacto blade and it didn't work that well for me I think a trip to the hardware store to see what round objects I can find

rgburrill

An xacto knife will fit in a compass.

All Day Dan

My Feedback: (5)

Forstner bit. Dan

NCRC

My Feedback: (32)

I 2nd the forstner bit, just use a similar piece of wood under the the wood you intend to cut.
High speed works best for me.

DGrant

My Feedback: (4)

Either a forstner bit, or a sharpened brass tube for smaller 1/2"+ size holes, and/or a small tin can sharpened on one end for the larger holes. Sharpen both the inside and outside diameters of either of these, and they should cut very decently just by hand. A smaller sharpened brass tube will even cut angles very nicely for pushrod exits and such, and they won't tear the wood, rather they'll cut it like a razor.. very clean.

speedracerntrixie

My Feedback: (29)

I have had great results using hole saws. They have to be really sharp and the Milwaukee brand work best. A drill press set to its highest speed is also required.

Jennifer Curtis

I usually find something like a jar lid or
can the size I need and cut around it
with an xacto knife.

Jenny

Propworn

My Feedback: (3)

Router table and a 1/16 bit just above the wood, lay out the hole with a compass, poke the bit through and cut to the line. WATCH YOUR FINGERS USE CLEAR PLASTIC GUARD IF YOU HAVE ONE. Think dremel makes a small router table for their rotary tool.

Lay out the hole poke a hole in the centre use a scroll saw feed the blade through the hole and cut to line.

Hydro Junkie

Another option would be to draw your hole using a circle template, cut the hole undersized from what you actually need and sand it to size with a drum sander of some sort. This works well with all balsas, ply and lite ply