Hi there, I used to get FHB for three or four years but let my subscription lapse. Great publication. I’m going to be installing an undermount kitchen sink in a butcher block couter top. What is the best was to cut out the opening to get a perefect cut? I think I know the answer but I thought I’d ask the big boys. Also, if anyone knows if this topic has been covered in a FHB publication it would be great to know which one. Thanks Darren
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Hi Darren. No big boy here but here's how I do it.
Although you can use the sink as template but I would make a separate template and try it on the sink to make sure you have the exact opening that you want.
Rough cut the open and rout the final edge with a edge bearing guide bit using the template. Be very careful not to burn the wood so you want to have minimal wood left before you do the final pass.
Don't forget to seal the edge really good.
One of the editors talked to me about an article on this subject but they seem to have lost intresst so I'll give it away here for you. Maybe even a photo.
I make a template from 3/16" or 1/4" tempered hardboard. It is easy to fine tune it smooth with plane or sandpaper.
Then I trace it to the BB material, and cut to the inside of the line with my bosch jigsaw. After that, it is a fairly easy job to clamp the tempered template on, and run a router with bearing around the hole. a straight cutting bit first to smooth it all th eway through the thickness, and then a roundover bit.
Then I flip the counter over and use a mortise bit to remove just enough material to compensate for the thickness of the sink edge.
After is is all sanded up fine and smooth, I use epoxy to seal the end grain of that wood, otherwise, the water will soon destroy the job.
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