We built this bedroom wall with mall led spits in the walnut veneer soffit. These lights were spec'fdvby designer. The client wants stronger spots which require a wider diameter cut out. Do not want to damage veneer as it's a satin flat finish and need your help on best way to increase the diameter. Jig saw will not be possible . Was thinking of glueing in a disc of plywood, letting it dry and then reboring using a hole saw. Client is an hour away from our shop and do not want to do multiple trips if possible and glue will take time to dry. Any sugggestions?

Drill a piece of plywood with the needed hole saw size.

Center the piece of plywood over the existing hole and drill the larger hole with the required hole saw. (clamp the plywood in place.)

JB Weld 5 minute epoxy is thick/controlable, fast and strong.

A router guide template stuck w/ two sided tape, e.g. a thin 3M (not FastCap). It doesn't take much and presticking (time = stronger bond) it to a melamine template (1/4" 1 or 2x) should leave it there (VS soffit).

Thanks. I like your idea pat. Can't clamp it but could use 23guage nailer or double sided tape.

Harold:

What I do in these circumstances is to have a rabbet bearing bit in one router and a top bearing flush trim bit in another router.

Place some blue painters tape over the opening area so the routers don't scratch the finish. Let the rabbeting bit bearing ride on the hole, then ride the top bearing flush bit on the rabbet.

You can gauge the size of rabbeting bit you need based on how much bigger the opening needs to be, perhaps doing multiple passes of rabbeting and flush trimming if needed.

Hope this helps.
TonyF

Thanks for the idea Tony. Operating the router upside down will be a little difficult, I think pats idea is the simplest. Harold.

Lenox makes a arbor that you use in place of pilot bit in a hole saw. It holds the smaller hole saw inside the larger letting you drill a larger hole perfectly centered on the smaller . I think I saw one from mcfeelys , I got my locally

If its only a few LEDS we have used a Dremel with a circular sanding head and sand to the new opening, about 1 minute per opening with sharp paper. Not too much mess and one tool to deal with, finally did clean up with a shop vac.

Once "Jig" is in place start cut slowly and increase with depth. I am sure You guys will test like crazy before the actual cut.

We've done the hole in a plywood thing before. Find a way to wedge in or clamp. I also think, but not sure, that we've done the hole saw within a hole saw method.

Use hot melt glue gun for the disk. Drill away.

Use the supersize square LED that is less than 1/4" thick from hafele and cover the hole.

I don't think it's been mentioned but how much bigger does it have to be. One trick I've used in the past, if I need to increase the diameter by 1/4" let's say is to use an 1/8" roundover bit, sunk deep enough to create a vertical face with an 1/8" offset from the original hole. Then I use a top bearing straight bit to run on that face. It works easy enough if you know how much bigger you need to go, and have a roundover bit (or rabbet bit) that will accommodate the change.