Cutting holes in kitchen cupboards for downlights

[Deluks]

I've gotta flush mount some low voltage lights into the bottom of a kitchen wall unit. The wiring will go up in and out the back, and a step-up shelf fitted halfway in to cover wiring.
What's best way to do it?
Is there such thing as circle jig for a router?

 

[Jasonb]

You can get circle templates but the holes they produce are quite small, Trend do one and I think Rutlands sell one by Dakota.

You can buy router compasses which allow you to cut circular holes with the router or its easy to make your own. Assuming the hole will not go all the way through the shelf, use the compass att to make a template the size you need then fix this to cabinets with clamps and cut.

I've done the same thing several times but use an extralong bradpoint drill to drill a hole from recess to back of cabinet/shelf to thread the wire through.

Jason

 

[Deluks]

Initially I was going to recess the lights into the board and drill from the back to feed cable through. but as the lights need 16mm depth and the carcasses are 18mm, I decided it wasn't worth leaving just 2mm (the melamine) thickness above the light.

Instead I'm going to utilise a spare shelf from inside the unit, cut that into 2 lengths and make a half-shelf to go into the bottom of the cupboard, at the back. like a step up. This will make it easier to find those going-out-of-date tins at the back of the cupboard, as they will be sitting slightly higher than the stuff at the front.

The light cables and transformer can sit inside this 'box'

So finally, the hole can go straight through, I wasn't keen on using jiggy for this, my holes always come out elliptical, plus it'll gash the edging.

The hole needs to be 62mm.

 

[Jasonb]

If i'm fitting them into the tops of units then I just go through with a hole saw, 60mm works for the ones I generally use (TLC) the flange at the front will cover any ragged edges, try your holesaw on a bit of scrap first and make sure its sharp

Jason