How to make holes in posts?

[Tappet]

I wonder about something that I don't know how to explain, but I'll give it a try.

Suppose—just for the sake of example—that I am building a fence consisting of:
* Two fence posts, 70 x 70 mm.
* Two horizontal beams (45 x 45 mm)
(...as well as a number of fence slats.)

I want to attach the beams by "cutting out" 45 x 45 mm holes in the posts into which I "insert" the beams. The holes in the posts don't go "straight through," but maybe halfway.

Which technique and tools are suggested for this?

I hope someone understands what I mean...

P.S.
As I said: The fence is just an example. The day I really build a fence, I'll go for a different technique and other dimensions for the timber.

 

[cheetah1]

Router to mill with, then a super sharp chisel to cut out the corners to make it square. That's what I would have done. Alternatively, drill straight through and saw out the hole with a jigsaw, and only use the above technique on the ends (because I assume you will ultimately have more fence posts than 2?).

 

[mrVoodoo]

Now I actually became a little unsure of what it's called in Swedish, but a mortiser (I'm guessing, it might have another name) can make square holes. Maybe you should even say quadrilateral holes, then you should be able to move around and use it multiple times if you want rectangular holes in any direction.

But as far as I know, it's a bit more expensive (I haven't seen any particularly cheap ones) and rather specialized, nothing the average DIY enthusiast goes and buys.

Personally, I would probably go for a drill of suitable size (I would probably use a cylinder drill) and then fix the rest with a sharp chisel, actually quite simple and quickly done with a good chisel if you're not working with oak or some other very hard wood.

Bah, I need to be quicker at writing Cheetah1's suggestion with a router might be even more effective if you happen to already own one. (Otherwise, there's always a reason to buy one )

 

[Tappet]

Router to carve out, then a very sharp chisel to cut out the corners to make it square. That's what I would have done. Alternatively, drill straight through and saw out the hole with a jigsaw, and just use the above technique on the ends (because I assume you will eventually have more fence posts than 2?).

Thanks for the tip. I've never used a router before but might consider getting one - if it's useful.

Do you mean you rout out round holes with it, and then make the hole square with a chisel?

I personally would have gone for a drill of suitable size (I would guess I’d use a cylinder drill) and then finish the rest with a sharp chisel, actually quite simple and quick to fix with a good chisel if you're not working with oak or some other very hard wood.

That is: Drill out as much as possible with a round drill, and tidy up with a chisel? Or...?

 

[mrVoodoo]

In other words: Drill away as much as possible with a round drill, and tidy up with a chisel? Or...?

Yep, correct It's basically the same thing as with the router, but with the router you have the ability to remove a bit more material, depending on how large/small the diameter of the router bit you're running is.

No, you're not routing a round hole (which it would be if you drilled); you're routing a hole with the dimensions you need, say 45*45mm, but then you'll have some material left in the corners that you need to remove, because the router bit is round. Say you're routing with a 15mm bit, then the rounded corners left in the square will have a radius of 15mm. But all in all, there's a bit less to remove compared to just drilling a round hole. However, nothing stops you from drilling multiple holes, but it will still be a bit easier and less to remove with a router.

A drill is probably a cheaper option than the router anyway, and will surely work great if you already have a drill? Personally, I might have routed too, upon closer consideration, but then again, I already have two routers...

 

[byggare henke]

hello
this machine is available
http://www.bosch-do-it.se/boptocs2-...=sv&division=hw&ccat_id=95226&object_id=14153

 

[Tappet]

Yep, correct It becomes basically the same thing as with the milling machine, but you have the ability to remove a bit more material with the milling machine, depending on how large/small diameter you're using for the milling cutter.

No, you don't mill a round hole (like it would be if you drilled), you mill a hole with the dimensions you need, say 45*45mm, but then you'll have a bit left in the corners that you need to remove because the milling cutter is round. Say you're milling with a 15mm cutter, then the rounded corners left in the square will have a radius of 15mm. But all in all, a bit less to remove than if you just drilled a round hole. However, there's nothing stopping you from drilling several holes, but it would still be a bit easier and less to remove with a milling machine.

A drill is probably a cheaper option than the milling machine anyway, and would likely work great too, if you already have a drill? I might have milled it too upon further reflection, but then again, I already have two milling machines...

Interesting!

New naive question: Can you set the depth of the hole so that all holes are equally deep?

 

[byggare henke]

yep. can't say how deep max is, but it can be adjusted.

 

[mrVoodoo]

With the router, you have an adjustable depth stop, but keep in mind how deep you want to make the holes. Depending on the router and router bit, it may be difficult to achieve any significant depth with a router; I wouldn't expect to rout much deeper than 40-50mm. That would already be quite deep for the hypothetical fence you mentioned above

For drills, you usually get a depth stop, but with a screwdriver (which is actually what I mostly use for drilling), it is fairly uncommon. For smaller drill sizes, there are so-called drill stops, a small ring that you slide over the drill bit and lock at the desired depth (mainly when drilling and plugging wood dowels). Personally, I usually wrap a couple of turns of tape around the drill bit to mark where to stop; it works well as long as precise millimeter accuracy is not necessary, then I use a drill stand.

 

[Tappet]

With the router, you have an adjustable depth stop, but keep in mind how deep the holes you want to make are. Depending on the router and router bit, it can be difficult to achieve any significant depths with a router; more than 40-50mm deep I wouldn't count on being able to route. That would already be quite deep, though, for the fictional fence you mentioned as an example above

For drills, you usually get a depth stop, but for those you use with a screwdriver (which is probably what I drill with the most), it is quite rare. For smaller drill dimensions, there are so-called drill stops, a small ring that you slide over the drill bit and lock at the desired depth (mainly when drilling and plugging with wooden plugs). Personally, I usually wrap a couple of rounds of tape around the drill bit to mark where to stop; it works well as long as you're not dealing with absolute millimeter precision, then the drill press comes out.

40-50 mm depth is more than sufficient.

It seems I'll be purchasing a hand-held router tomorrow...

 

[mrVoodoo]

If you get one, practice a bit on scrap pieces first, it can take some time to get completely comfortable with your router. Once you've become a "router user" though, the router comes out regularly, at least for me

 

[pbengtsson]

Another option is to buy angle irons that you use to attach 2"2 to the posts. A bit cheaper than buying a router, but not as neat.