FHB Logo Facebook LinkedIn Email Pinterest Twitter X Instagram Tiktok YouTube Plus Icon Close Icon Navigation Search Icon Navigation Search Icon Arrow Down Icon Video Guide Icon Article Guide Icon Modal Close Icon Guide Search Icon Skip to content
Subscribe
Log In
  • How-To
  • Design
  • Tools & Materials
  • Restoration
  • Videos
  • Blogs
  • Forum
  • Magazine
  • Members
  • FHB House
  • Podcast
Log In
Mastered in a Minute

How to Cut Window and Door Openings With a Router

Mastered in a Minute: Panel pilot bits make clean cuts flush with the framing.

By Matthew Millham
  • X
  • facebook
  • linkedin
  • pinterest
  • email
  • add to favorites Log in or Sign up to save your favorite articles
Video Player is loading.
Current Time 0:00
/
Duration 0:00
Loaded: 0%
Stream Type LIVE
Remaining Time -0:00
 
1x
    • Chapters
    • descriptions off, selected
    • captions settings, opens captions settings dialog
    • captions off, selected

      This is a modal window.

      Beginning of dialog window. Escape will cancel and close the window.

      Text
      Background
      Window
      Font Size
      Text Edge Style
      Font Family

      End of dialog window.

      This is a modal window. This modal can be closed by pressing the Escape key or activating the close button.

      This is a modal window. This modal can be closed by pressing the Escape key or activating the close button.

      Using a router and panel pilot bit is a fast and accurate method to cut out window and door openings.  Here’s how to do it.

      First, install the panel pilot bit in a router with a 1/2-in. collet, a plunge base, and at least a 1-3/4-hp motor. Then, set the bit depth so the bit’s tip will penetrate entirely through the sheathing, the pilot will ride against the framing, and the cutter (or cutters) will contact the full depth of the sheathing.

      To start the cut, position the router near an inside edge of the opening, turn the router on, grip the tool firmly with both hands, and plunge the router into the sheathing. Then guide the router in a straight line until you find the edge of the rough opening. Once you’ve contacted the framing, run the router clockwise around the opening. By keeping the pilot shaft tight against the rough opening, the cut will be an exact match to the framing.

      Make sure to keep the router moving as you make the cut. Letting the bit dwell in one place for too long will cause it to heat up, which can shorten its life and leave burn marks around the opening.

      With the cut complete, you’re ready to stand up the wall.

      Sign up for eletters today and get the latest how-to from Fine Homebuilding, plus special offers.

      Signing you up...

      This site is protected by reCAPTCHA and the Google Privacy Policy and Terms of Service apply.
      See all newsletters
      See all newsletters
      ×

      Get home building tips, offers, and expert advice in your inbox

      Signing you up...

      This site is protected by reCAPTCHA and the Google Privacy Policy and Terms of Service apply.
      See all newsletters
      See all newsletters

      New Feature

      Fine Homebuilding Forums

      Ask questions, offer advice, and share your work

      • X
      • facebook
      • linkedin
      • pinterest
      • email
      • add to favorites Log in or Sign up to save your favorite articles

      View Comments

      1. user-6572928 | Jul 19, 2018 02:24pm | #1

        Couldn't you use a drill bit to start?

      2. user-6572928 | Jul 19, 2018 02:26pm | #2

        meant to add, "and use a flush trim bit?

      3. WinnifredRBoyles | Aug 10, 2018 06:37am | #3

        Well done!! I really like your blog...

      4. MattMillham | Aug 31, 2018 02:05pm | #4

        Hi user-6572928 - You could do that, but I'd use a drill bit that's quite a bit larger than the router bit for the initial hole for safety. The nice thing about the panel pilot bits is that they're made for this application, and there's no need to switch between tools. Another thing to consider: the adhesives in OSB and plywood can be harder on the bits than raw wood, and a good flush trim bit could get worn out quickly or made relatively useless for other tasks.

      Log in or create an account to post a comment.

      Sign up Log in

      Become a member and get full access to FineHomebuilding.com

      More Mastered in a Minute

      View All
      • Fastening an Exterior Door With Brick Mold
      • Assemble Housed Stairs With Construction Adhesive
      • Insulating Foam for High-Performance Windows
      • Air-Seal Penetrations With Canned Foam
      View All

      Up Next

      Video Shorts

      Featured Story

      Tools and Gear for the Moms Who Get it Done

      From work boots to power tools, these favorite picks make perfect gifts for moms and women who build.

      Featured Video

      Video: Build a Fireplace, Brick by Brick

      Watch mason Mike Mehaffey construct a traditional-style fireplace that burns well and meets current building codes.

      Related Stories

      • Beat the Heat: Cool Innovations
      • Precut Bottom Plates in Doorways
      • Breathing New Life into Original Windows
      • Mortising a Hinge without a Router

      Discussion Forum

      Recent Posts and Replies

      • |
      • |
      • |
      • |
      • |
      • |
      View More Create Post

      Highlights

      Fine Homebuilding All Access
      Fine Homebuilding Podcast
      Tool Tech
      Plus, get an extra 20% off with code GIFT20

      Video

      View All Videos
      • Fastening an Exterior Door With Brick Mold
      • Building a Flush Interior Door With Carpenter Casey Knips
      • Podcast Episode 627: Leaky Doors, Flashing, and Kneewalls
      • Podcast 380: 40th FHB-Anniversary-Edition Interview With Gary Katz
      View All

      Routers

      View All Routers Articles
      • Strong Connections With Loose Tenons
      • Hybrid-Powered Router
      • Tool Test: Compact Cordless Routers
      View All Routers Articles

      Fine Homebuilding Magazine

      • Issue 331 - June 2025
        • A More Resilient Roof
        • Tool Test: You Need a Drywall Sander
        • Ducted vs. Ductless Heat Pumps
      • Issue 330 - April/May 2025
        • Deck Details for Durability
        • FAQs on HPWHs
        • 10 Tips for a Long-Lasting Paint Job
      • Issue 329 - Feb/Mar 2025
        • Smart Foundation for a Small Addition
        • A Kominka Comes West
        • Making Small Kitchens Work
      • Issue 328 - Dec/Jan 2024
        • How a Pro Replaces Columns
        • Passive House 3.0
        • Tool Test: Compact Line Lasers
      • Issue 327 - November 2024
        • Repairing Damaged Walls and Ceilings
        • Plumbing Protection
        • Talking Shop

      Fine Home Building

      Newsletter Sign-up

      • Fine Homebuilding

        Home building tips, offers, and expert advice in your inbox.

      • Green Building Advisor

        Building science and energy efficiency advice, plus special offers, in your inbox.

      • Old House Journal

        Repair, renovation, and restoration tips, plus special offers, in your inbox.

      Signing you up...

      This site is protected by reCAPTCHA and the Google Privacy Policy and Terms of Service apply.
      See all newsletters

      Follow

      • Fine Homebuilding

        Dig into cutting-edge approaches and decades of proven solutions with total access to our experts and tradespeople.

        Start Free Trial Now
        • Facebook
        • Instagram
        • X
        • LinkedIn
      • GBA Prime

        Get instant access to the latest developments in green building, research, and reports from the field.

        Start Free Trial Now
        • Facebook
        • YouTube
      • Old House Journal

        Learn how to restore, repair, update, and decorate your home.

        Subscribe Now
        • Facebook
        • Instagram
        • X
      • Fine Homebuilding

        Dig into cutting-edge approaches and decades of proven solutions with total access to our experts and tradespeople.

        Start Free Trial Now
        • Facebook
        • Instagram
        • X
        • LinkedIn
      • GBA Prime

        Get instant access to the latest developments in green building, research, and reports from the field.

        Start Free Trial Now
        • Facebook
        • YouTube
      • Old House Journal

        Learn how to restore, repair, update, and decorate your home.

        Subscribe Now
        • Facebook
        • Instagram
        • X

      Membership & Magazine

      • Online Archive
      • Start Free Trial
      • Magazine Subscription
      • Magazine Renewal
      • Gift a Subscription
      • Customer Support
      • Privacy Preferences
      • About
      • Contact
      • Advertise
      • Careers
      • Terms of Use
      • Site Map
      • Do not sell or share my information
      • Privacy Policy
      • Accessibility
      • California Privacy Rights

      © 2025 Active Interest Media. All rights reserved.

      Fine Homebuilding receives a commission for items purchased through links on this site, including Amazon Associates and other affiliate advertising programs.

      • Home Group
      • Antique Trader
      • Arts & Crafts Homes
      • Bank Note Reporter
      • Cabin Life
      • Cuisine at Home
      • Fine Gardening
      • Fine Woodworking
      • Green Building Advisor
      • Garden Gate
      • Horticulture
      • Keep Craft Alive
      • Log Home Living
      • Military Trader/Vehicles
      • Numismatic News
      • Numismaster
      • Old Cars Weekly
      • Old House Journal
      • Period Homes
      • Popular Woodworking
      • Script
      • ShopNotes
      • Sports Collectors Digest
      • Threads
      • Timber Home Living
      • Traditional Building
      • Woodsmith
      • World Coin News
      • Writer's Digest
      Active Interest Media logo
      X
      X
      This is a dialog window which overlays the main content of the page. The modal window is a 'site map' of the most critical areas of the site. Pressing the Escape (ESC) button will close the modal and bring you back to where you were on the page.

      Main Menu

      • How-To
      • Design
      • Tools & Materials
      • Video
      • Blogs
      • Forum
      • Project Guides
      • Reader Projects
      • Magazine
      • Members
      • FHB House

      Podcasts

      • FHB Podcast
      • ProTalk

      Webinars

      • Upcoming and On-Demand

      Podcasts

      • FHB Podcast
      • ProTalk

      Webinars

      • Upcoming and On-Demand

      Popular Topics

      • Kitchens
      • Business
      • Bedrooms
      • Roofs
      • Architecture and Design
      • Green Building
      • Decks
      • Framing
      • Safety
      • Remodeling
      • Bathrooms
      • Windows
      • Tilework
      • Ceilings
      • HVAC

      Magazine

      • Current Issue
      • Past Issues
      • Magazine Index
      • Subscribe
      • Online Archive
      • Author Guidelines

      All Access

      • Member Home
      • Start Free Trial
      • Gift Membership

      Online Learning

      • Courses
      • Project Guides
      • Reader Projects
      • Podcast

      More

      • FHB Ambassadors
      • FHB House
      • Customer Support

      Account

      • Log In
      • Join

      Newsletter

      Get home building tips, offers, and expert advice in your inbox

      Signing you up...

      This site is protected by reCAPTCHA and the Google Privacy Policy and Terms of Service apply.
      See all newsletters
      See all newsletters

      Follow

      • X
      • YouTube
      • instagram
      • facebook
      • pinterest
      • Tiktok

      Join All Access

      Become a member and get instant access to thousands of videos, how-tos, tool reviews, and design features.

      Start Your Free Trial

      Subscribe

      FHB Magazine

      Start your subscription today and save up to 81%

      Subscribe

      We hope you’ve enjoyed your free articles. To keep reading, become a member today.

      Get complete site access to expert advice, how-to videos, Code Check, and more, plus the print magazine.

      Start your FREE trial

      Already a member? Log in

      Privacy Policy Update

      We use cookies, pixels, script and other tracking technologies to analyze and improve our service, to improve and personalize content, and for advertising to you. We also share information about your use of our site with third-party social media, advertising and analytics partners. You can view our Privacy Policy here and our Terms of Use here.

      Cookies

      Analytics

      These cookies help us track site metrics to improve our sites and provide a better user experience.

      Advertising/Social Media

      These cookies are used to serve advertisements aligned with your interests.

      Essential

      These cookies are required to provide basic functions like page navigation and access to secure areas of the website.

      Delete My Data

      Delete all cookies and associated data