ISO: Idiots Guide to Cutting Slots. :P

Frax

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Okay maybe not that much, but is it possible to get a good result using a handheld router of some type to recut cabinet slots? The ones on my Nintendo cabs are pretty banged up including some corner damage. Was considering just filling the slots with wood filler or bondo or something, then completely recutting them once I've got the whole thing sanded flat...

Just wondering if I'm gonna have to make some kind of rube goldberg machine to get a good slot or if this is a pipe dream... Don't really have room for a table+slot cutter getup...not sure that's even practical with a fully assembled cabinet anyways.
 
I always cut slots with a hand held router, and a 1/16" bit fitted with a bearing to follow the cabinet edge.

With that said, for banged up slots without cab side damage, you might not need to fill and recut, depending on how bad the damage is. Bondo will sometimes chip out when you attempt the slot cut, and you'll end up with a bigger mess than you started with.

If the slots are just loose, you can use hot glue + an ice pack. We've got those gel ones that work great, but a bag if ice will do fine too. Just fill a few inches of the slot, lay in the t-molding and press hard with the ice pack to set it instantly. Then keep working along the slot until you reach the end.

Only glue the loose areas, there's no need to glue the entire length of the cab or some collector 40 years from now will be cursing your effort :)
 
Router is the best way but I have also cut them free hand with a dremel style tool and a cutting disc. Worse case is you mess up and have to fill it with bondo and start over.
 
Router is the best way but I have also cut them free hand with a dremel style tool and a cutting disc. Worse case is you mess up and have to fill it with bondo and start over.

That's exactly what I use. I also used a handsaw that was the exact width once.
 
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