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In my kitchen I have a dumb waiter; the door is 1" thick solid wood wrapped in 1/16" sheet metal. I removed the old door knob (that's the hole in the photo) to make room for a flush pull. I need to cut the sheet metal in the shape of the pull to make it fit, but I'm not sure how to do this. I can't use clippers and I don't own a router; I have a Dremel and power drill only. I could drill holes along the cut out line using the power drill, but there's gotta be a better way.

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  • I would take it to a fabrication shop that has a plasma cutter. – Alaska Man Jan 6 at 18:02
  • Is there an alternative option? emphasis "diy" – raffian Jan 6 at 19:15
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I think the Dremel tool with a cutoff wheel will be about as good as it gets for this application.

Scoring the line (not too deeply) with a cold chisel should help make a channel for the wheel to follow.

I'd tape up the rest of the surface before you start, so you don't have sparks and dirt marring the finish.

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    A dremel with a cut off tool will work great it may take quite a few disks , and be sure to wear safety glasses but of the tools you have it can do the job.+ – Ed Beal Jan 7 at 13:19
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    Yep, that's how I'm doing it; I'll post an update next week! – raffian Jan 7 at 18:45
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Best for you to draw a inside and outside max liwas of the part it looks like u have a have play room about half to three quarter of inch I material fabercater years ago Gininder and meatal file don't think that a dremel will do it but maybe u would have to drill a bunch of little holes inside lines first then jig saw meatal blade then grind with dremel I have a dremel roto zip it would do it all itself I recommend every on should have one be careful it's a monster

  • I'm trying the Dremel route first – raffian Jan 7 at 2:22

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