DIY question: cut out rectangular notch on wooden door

[Sideshow Bob]

DIY experts here, please advise if you can. I want to cut out a rectangular notch - 2 notches (about 3.6cm x 2.5cm and 2cm in depth each) in a wooden sliding door with glass panes. I tried searching for "square drill bit" and apparently it is possible but I didn't find this particular drill bit at the shops (builders warehouse/express) - all the shop assistants looked at me with you-must-be-crazy-eyes when I mentioned "square drill bit".

Alternatively, I was thinking of drilling round notch (as per size) and then chiseling the rest of it out. And no, I can't remove the door as it is a heavy sliding door. Anyone?

 

[APoc184]

Use a very small drill bit. Drill plenty of holes in designated area and just chisel out the bits that remain.

It'll even come out with a flat screwdriver if you don't have a chisel

 

[OGroteKoning]

The square drill bits normally have to be mounted on a one of these bench drills because the casing needs to be secured while the drill itself has to turn inside it. I don't know if such a bit exists for a hand held drill. I recon you are going to chisel away unfortunately

 

[bwana]

Router?

 

[ToxicBunny]

Router would possibly do the job...

With a bit of creativity a Jigsaw could possibly help as well.

 

[Sideshow Bob]

@APoc184 and @OGroteKonig - cool, will go with drilling small holes and chisel the rest then.
@bwana - good suggestion but don't have router

Thanks for the replies guys.

 

[bwana]

Router would possibly do the job...

With a bit of creativity a Jigsaw could possibly help as well.

I was also thinking jigsaw initially but wasn't sure if the notch was through and through or not.

 

[Sideshow Bob]

Router would possibly do the job...
With a bit of creativity a Jigsaw could possibly help as well.

Wow - forgot I have got jigsaw (sho - have bought lot of DIY tools when on special and lying unused in garage) - let me experiment on a piece of wood before I demolish the door. Thanks

 

[furpile]

You could drill the corners with a 6mm drill bit and then use a jigsaw to cut between the holes. Won't be super smooth but it's easy to do.

 

[furpile]

You could drill the corners with a 6mm drill bit and then use a jigsaw to cut between the holes. Won't be super smooth but it's easy to do.

Wow, lots of posts between opening this page and eventually replying

 

[OGroteKoning]

You could drill the corners with a 6mm drill bit and then use a jigsaw to cut between the holes. Won't be super smooth but it's easy to do.

I never did that. I always drill in the "waste" area and work my way to the corners to get it perfect

 

[furpile]

I never did that. I always drill in the "waste" area and work my way to the corners to get it perfect

Yeah, it depends what you want the hole for. If you are going to fit something in it that will cover it its not a big deal, but if the hole will be visible its worth doing it your way, and maybe filing the edges afterward to get it smooth.