2 tool tips

[Daniel]

Using a hand drill with guides helps in making completely vertical pilot holes if you dont have a drill press. Ive had plenty of screws pop out sideways in the past because of inaccurate pilot hole drilling.

http://www.frappr.com/fitzmaurice/photos/3511160

Using a circular saw is definetely the way to cut out access panels. What you want to do is plunge cut with the circular saw on all 4 sides, then trim off the extra bit in the corners carefully with a saber saw.

http://www.frappr.com/fitzmaurice/photos/3511210

I initially tried to make a plunge-cut with a saber saw---not easy! After chewing at the wood, bending a blade, but not making any real progress, i went "duhhhh--use a circular saw!" The one shown here is one we scored from a construction worker that left it at our house and never came back. It is actually meant for cutting tile, but works great for wood. This crazy little beastie of a saw spins at something like 13000 rpm, and the gaurd is broken, but man, it does some good, clean plunge cuts.

[klocwerk]

Great thoughts, but for people who've never tried it before, be VERY careful doing plunge cuts with a circular saw. Get the saw up to speed before touching wood, take it super slow and keep those fingers well clear.

Can be very dangerous if things go wrong.

[Bill Fitzmaurice]

The best way to cut the access panels is with a circular saw and sled, that way the cut will be absolutely straight.

[fender3x]

This is still my favorite way to do it...used it again today

http://billfitzmaurice.com/phpBB2/viewtopic.php?t=1039