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Originally Posted by Luke Sheridan I've considered this myself and i don't think its that tough if you have a router, a tight bit for the corners and some sandpaper.
I would lay them out on a wide piece of wood for stability and then route the cavity. Then I'd cut and shape to size. It doesn't appear that difficult, but I'm sure someone will chime in. |
Use a 3/16" round bit (spiral if you can get it) and you'll be fine in the corners. Do like Luke said and you won't be trying to hold down a tiny piece of wood while hollowing it out.
If you want to make sure you've got a really thin top and don't want to hassle with making sure you're plunging to the right depth, then cut all the way through and then just glue a piece of veneer to the top of your frame like in the pic. Sand, paint or stain, finish and your done.
If you want more room inside the cover, buy a set of replacement plastic covers and carve off the ears before laying out your pattern on the wood.