How To Cut A Square Hole In Wood – Proven Method

Are you curious about “how to cut a square hole in the wood?” Or are you a part of woodworking and want to know different tricks or techniques related to the topic?

Here, we will facilitate you with enough information about this topic and a mistake-proof guide in this article. For this, you have to go through this article from top to bottom. 

 But before looking at the procedures, let’s have a guide about precautions and tools. Are you ready?

Let’s fall into it.

Precautions And Tools- How To Cut A Square Hole In Wood

Here are the safety measures to follow:

  • Use a pair of safety goggles while using any power tool. 
  • For working, use a room that is airy and has outdoor space.
  • Follow the instructions given with the power tool. 
  • Wear a complete uniform for this work. Uniform includes mask, goggles, closed shoes). 
  • Use a sharp blade for cutting. 
  • Keep your focus at work to avoid any mistakes. 

So, these are the precautions. The most important thing is to keep focusing on work. Because the slightest in measurement can lead you to a big disaster. However, you need to pay keen attention whenever using cutting tools.


Some tools are used besides cutting tools. These tools are as essential as other cutting tools. These tools will differ according to the method you will be using. 

So, let’s see the tools to cut a perfect square hole in the wood with a router. 

  • A router
  • Measuring tape
  • Pencil
  • Protractor
  • Straightedge
  • Sandpaper
  • Wood file
  • Safety goggles
  • Drilling machine
  • Gloves 
  • Dust mask
  • Vacuum Cleaner 

Now, let’s move toward the procedure of “how to cut a hole in wood in a router.”

Outline the Square in A Wood

You need to take wood and create a lineup of the square at this point. This lineup will be the direction for your cutting. For measuring the precise length and width, a measuring tape can be used, and then pinpoint the layout with a pencil. For better perfection, the center point of the wood can be selected. This whole point is used to get the accuracy for cutting squares and gain accurate square corners; use the protractor.

The desirable angles of the corner could be around 45 degrees. If you keep this measurement, the square will look aligned from all sides. Ensure that the pencil is sharp enough so that your drawing looks visible from any distance.

Cut Square Hole With A Router

Experience is required for practicing this router machine. It is an advanced technique and not suitable for beginners. It is because it requires more practice for using it. It is unique from all the above methods because it saves your time and effort and is excellent for thick wood.

How To Use It

  1. Be precise when you design a template on a router table. It determines the result. 
  2. Use template guide for creating template and router bits. 
  3. You need to add 0.35 inches to each line of the template. 
  4. Drill an exploratory drill hole in one corner of the square on the wood sheet.
  5. Use an exploratory hole and line up the router fence with the square you want to cut.
  6. Switch the router on and let it cut along one straight line.
  7. Pause the router and rotate the square to cut through another line.
  8. Repeat the last three steps on all the square lines.

If you are an experienced cutter, you might already be clean. But if you are a beginner, you will find some areas of edges to be finished. For this, sandpaper is used to smooth the edges. The jagged edges will be removed, and you can use the piece of wood in your projects. 

Begin with low grit sandpaper to work on half-done areas. Then, copy this step a few times with a higher grit paper until you get to 320 grit. By doing this, your work will be as smooth as you want it to be.

Sand The Edges

All the essential procedures are done, and now you can have an easy breath. Take a sigh of relief for a couple of minutes if you prefer. This new hole will help you in your wooden project. Sandpaper is used to sand the edges of wooden squares. But keep in mind, if you sand them with pressure, they will end up with round-shaped edges. 

You must know grit sequences. Therefore, you will know which one is best for working according to the situation of wood. 

Moreover, lower grit sandpaper is used on rough edges, and the higher grit sandpaper is applied for smoothening purposes. 

Apart from all, wood files can be applied for extra smoothness on the edges. Now, use a vacuum cleaner to clean an area.

Tips-How To Cut A Square Hole In The Wood With A Router

  • Wear safety gear which includes: goggles, dust masks, closed shoes, etc. 
  • It would help if you worked in a room with ventilation and outdoors because wooden work creates a cloud of massive dust.
  • This project is time-consuming. So, make yourself ready for it, or else you can make a schedule. 
  • Read the handbook given with the power tool to remember all the features and use them like a pro. 
  • Check the blade of the cutting sharp. 
  • Sharpen the cutting tools if they are not blunt.

Frequently Asked Questions

A few of the questions you frequently ask about “how to cut a square hole in the wood with a router” are also answered in this article. Let’s have a look at them. 

1. What Tool do I Use To Cut A Square Hole In A Wood? 

Four tools can be used for this purpose. You can cut a square:

  1. With a chisel
  2. With a drill and a saw
  3. With a router
  4. With a jigsaw

2. How Do I Cut A Groove In A Wood?

If you want to cut a groove in a piece of wood, a plunge router is a convenient tool to use for straight or curved grooves. Using a rotary tool also works for cutting short channels, but it’s more difficult to make long, straight lines with them.

3. How Do I Cut A Square Hole In A Wood? 

  1. Position the chisel’s tip on a corner of the square you have created.
  2. Tap on the chisel with a sledgehammer as hard as possible.
  3. Keep tapping until it cuts through the whole wood thickness.
  4. Repeat the above steps for each corner.
  5. Cut the square out.

The Conclusion

In conclusion, we have come to know that experience and practice are required for woodworking; you need to learn how to cut square holes in wood with a router. Besides this, do not let slip take complete precautions such as protective work clothes to stay safe from wood particles and dust.

Hopefully, we have provided you with enough knowledge about your problems in this article. We believe that it will help you to accomplish your project! 

Kenneth Wafer Woodnami

Kenneth Wafer is an aspiring woodworking expert from Los Angeles. He loves reading and writing about all the best woodworking tools and accessories available in the market.
He is a Finance professional and recently completed his foundation course from CFA Institute, USA.

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