Need instructions on cutting a clean square hole

[asianjedi]

I know this really insist an audio topic but the skills needed are the same as flush mounting an amp, so......

The billet N20 bottle bracket I got looks great but it is about an 1/8 inch too high to accommodate the vert top bin and my fiberglass trunk shroud thingy.

So I need to cut a square hole in the 3/4 MDF, then attach another piece of wood to the bottom of the main piece. Then attach the bottle bracket.

Anyway, can anyone tell me how to cut a clean square hole in the wood. I tried before with a jigsaw and it was a train wreck.

Any advice is appreciated.

[325CI2004]

trace out the bracket. Drill holes in the corners and use a jigsaw with a good bit. You could also use a straightedge to help guide it.

Thats really the only way i could imagine

[ca1242]

The best way to get a perfectly square hole (assuming you have a router table + table saw):
1. grap a scrap piece of 1/2 mdf.
2. Cut some strips (3/4 - 1" thick) using a table saw.
3. using 3/4" brad nails, nail strips to MDF piece of scrap. You can use an existing square/rectangular piece, or use a square to measure.
4. rough cut the hole with a jigsaw (leave 1/8" to 1/4" from the edges).
5. Using a flush-trim bit, rout out the hole (using strips as guide)
6. trace, rough cut material you want to cut (leave 1/8" to 1/4" from the edges).
7. using doub;e-stick tape, secure it to the MDF piece.
8. rout out the hole on your final piece using the flush bit
9. If you have a smaller sice flush bit (they go down to 1/4" dia), you can trim the corners some more, then use a file to finish what is left of the corners.
5. Trace piece you want to cut