cuttinghand-toolsladderpowertoolsrouters
I am building a ladder similar to the one pictured. I want to cut hand-hold holes like the ones in the image.
I am horrible with a jig-saw, and I don't think I could ever get them looking as nice as those below with a jig-saw.
How did this person achieve the exact same holes? What tool/technique is best to achieve this. I want it to look as clean/professional/consistent as possible.
My experience says to use the rotary tool, but I have always used metal boxes with plaster rings. I have no experience cutting drywall over plastic boxes. I do have three pointers for cutting with a rotary tool:
If you still don't want to use the rotary tool, there is another option. There are tools that attach to plastic electric boxes. You put them on and then position the drywall where it will be installed. Press the drywall against the tool, and it will place small perforations at the outside corners of the box. Connect the dots and cut. The image below is of one of mine, but I haven't had the chance to use it yet.
If you're talking about railroad ties, just buy a cheap circular saw blade for about $5, use it for the railroad ties and then throw away. It won't go all the way through, even if using on all four sides, but will get close. You can then finish with a bow saw or just strike it against something to split it the rest of the way.
Best Answer
The most likely solution is to create a template and use a router with a bit that follows the template. The router would also be used for easing over any sharp edges.
photo credit, sample image, not a product recommendation