So ehh ... I'm in California. Where shall I get the wood? Will Home Depot work? I've never done this before.

Also, what kind of inexpensive tools do I need, including to cut the output lens hole?

Jon

Well Home Despot should be able to cut your wood to size. Add 2" to the over all length to give your self room to spare. For the hole you can get a 2.75" hole saw or just use a jigsaw to cut it.

What is another name (proper name) for a "hole saw"?

What kind of wood (again)? How thick?

You could use 1/2" or 3/4" plywood or MDF. If you use furniture grade plywood it will look better, but if you aren't planning on making a nice cabinet it would be a waste.

A hole saw is a hole saw.

I bought my 3/4" MDF from Home Depot and they couldn't cut a right angle to save their lives. Had it done twice!!!! Eventually I bought the wood and got in touch with a cabinet maker who cut it for $15. Cuts were perfect. If you look closely in Home Depot and Lowes they have signs posted that state they cannot guarantee precise cuts for safety reasons. Many others here have had a far better experience than me getting their wood cut at HD.

Is it a mere bit for a standard rotary power drill?

Not at all. There is a pilot bit that goes through the hole saw, this can be used to chuck into a standard 3/8" drill.

http://www.usahardware.com/inet/shop/item/..._tool/05244.htm

Better yet, for the hobbiest here's a kit that goes up to 5" for less than $10.

http://www.usahardware.com/inet/shop/item/...uffalo/hs19.htm

Thats figgin cheap!Im ordering one now.

Lowes wanted $17 for a single 2.75 hole saw.

Wow! That hole saw is a good deal. I just ordered one. Like ktulu909 said they go for well over $10 individually.

Bet that place will be sold out of those in the next couple of days.

Now you post a hole saw link, I just got mine a Lowes for $17 plus tax. :angry:

But mine was not made in China

Day late $$ short

I paid $25 for a 4 1/2" hole saw yesterday at HD for my fan. !##%#@

What about cutting the wood? Is a regular, circular saw alright? Why is cutting it to size so difficult? What about my pants, do they make me look fat?

I got my wood cut at Lowe's and they did a godawful job. If you look at the pictures of my projector in the Project Gallery you'll see tape all around the edges to block in the light. I recut the end pieces with a DeWalt saw to make it a little better. I wanted my box to be a rectangular cube and not a rhombohedron (always wanted to write that in a post).

h_ank, wear horizontally striped shirts like I do, it really trims you down.

God, I love this forum...

I really hate to burst any ones bubbles but I had my plywood cut at HD, the guy did a perfect job

You owe me a bubble. Also, since I do everything three-quarter assed anyway I shall be trying to cut the wood myself. Probably. I haven't even ordered anything but the plans yet, so who knows...

Brain
That hole saw set has a great price, but they don't disclose the various sizes. Most of those 16 piece sets are missing the 2-3/4" we need for the Triplet!
Here's a near identical set hole saws which lists the sizes included. (significantly more expensive, but the same thing)
Could someone verify if that USA Hardware 19 piece set includes a 2-3/4" hole saw?

Continuing the hole saw thread - I found this link
31 piece set

31 Pieces including that 2-3/4" hole saw for $25 +$6 shipping.

Check your link again, it goes for 25 with free shipping now

Good point. Definitely confirm it has the size you want.

[QUOTE=jeremyvnc,Mar 17 2004, 02:04 PM]
31 Pieces including that 2-3/4" hole saw for $25 +$6 shipping. [/QUOTE]
Check your link again, it goes for 25 with free shipping now

[/QUOTE]
Once you get to the checkout shipping is free, but Tool King charges a $6 "handling fee" on all orders no matter how big they are.

Ahh, the other evil brother. Shipping & handling. Well if they can't get you one way, they get you another....

DIY projector enclosures made to your custom size or standard “guide” size. Enclosure comes complete hardware included. "NO Bulb, LCD, Glass, Flashing"$50.00 each plus exact shipping to you. If interested contact hjsproductions@hotmail.com for further details. Thanks, HJSproductions