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Tonight I cut the oil door. Sam James recommends at least 4.5" by 5" for the cutout. I made mine 5.5" wide by 6" tall because I am going to use a 1/2" backer around the perimeter. The cutout was OK..not my best work, but it looks pretty good. Oh...I am going with a metal oil door made out of 0.050" sheet. Everyone who has made a door out of metal absolutely loves it.  So my backing strip needs to sit on a uniform distance from the surface. The only problem is there is there is thick epoxy on the front which is about 0.150" thick, the core epoxy is on the bottom (0.200" thick) and various thicknesses around the rest. I started out with using 60 grit sandpaper but that got old real fast. What ended up working GREAT is a sanding wheel on my die grinder. Everything is about 0.090 or less currently. I am going to take the rest down by hand since the die grinder can be a bit aggressive. 
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Last Modified: August 13, 2023 |