Quote Originally Posted by its_34 View Post
Thanks. I'm using a hole saw notcher. It's one of the cheap ones (no ball bearings, stamped steel guides) but it works for light use. It took quite a bit of shimming to get it to cut on center.

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I made some more progress today and will post some more pics later.
I've been seriously considering buying one of those cheaper holesaw notchers like you have, just so I have a complete tool that I can then modify as I see fit. I full well expect it to be light duty and inaccurate, but I still can't convince myself to buy one. I have almost all the materials to make my own, but do I really want one that bad? I have (and use quite often) a wood doweling jig that is a cheapy HF brand item, and yes, it's not centered either. But in all reality, once I figured that out, shimming it isn't really an issue anymore...and it has gotten me out of some tight jams in the past. Another $10 well spent.