Tricky project in a boat...
I'm back after a long absence, and have been enlisted to help my best mate modify the interior of his 43' launch.
He wants me to install some drawers - this involves making the carcasses, building the framework to support the drawers...and the tricky part : cutting the aperture for the drawer/making the faces for the drawers. This last step is what I'd like help with!
I need to cut three large apertures from a vertical face that up extends from floor level to about 400mm. So I'm picking the drawer aperture will be about 300mm tall, and perhaps 600mm wide. I need to use the cut-out (i.e. the timber 'plug' created by cutting the aperture) as the face of the drawer carcass. I understand that any cutting device I use will cause a loss of timber - kerf.
If I could cut accurately enough with a device with a thin kerf (saw 3mm) then I could use the 'plug' as the face of the drawer carcass without adding trim to the aperture edges. However, given the work area (i.e. vertical surface, close to floor and rail at top of work area), I don't like my chances!
I'm picking I have to cut the aperture with a jigsaw, then add trim to the edges of the aperture to tidy up from the rough jigsaw cut - then reduce the size of the 'plug' to match the aperture. Is that the best approach?
I'm a big fan of using templates and a handheld router, but can't see this approach working given the need to operate the router in a horizontal position (surely hard work!?!) and lack of space to manoeuvre the router near the floor and top rail. Also, I can't afford to have the router deviate from the intended path, as it'll chew up the surrounding timber if I use a male template, or the 'plug' if I use a female template. Or is there another way to do it : a 'channel' template & a template guide the same width as the channel??
Any help would be much appreciated!
PS - if a pic would help, let me know - I'm out on the boat tomorrow.