Cutting it on the CNC router was the most obvious solution, but the top was already cut to the exact size which leaves little room for error and no really easy way to secure the top to the bed of the router.
The quickest way would be to trace the template onto the top and then cut the hole with a jig saw, but this can be pretty sloppy and there’s a lot of sanding to do to the inside of the cut.
I ended up using making a template so I could use a hand router. This way I could be sure the cut was in the right place, parallel with the sides of the top, and with a clean cut on the inside edge.
The first step is to make a template to use as a guide for the router.
I made a file with the toolpaths and then cut the template from 1/4” plywood. The template is basically oversized by the distance from the edge of the router bit to the edge of the router plate. I made a few holes to indicate the centerline of the template, and a notch in the front edge so it would be the right distance from the front edge of the top.
Being worried about ruining the piece of wood, I made a few test cuts to make sure the template worked. Each time I made a test cut I found a small problem.
Second test cut:
after about 3 test cuts I figured out the tricks and was ready to cut the hole for real.
Each pass was made about 1/4 or 3/8” deep. After going halfway, the middle piece being cut out is screwed down so it doesn’t move. On the last pass that piece is liable to come loose and fly around and cause problems if you don’t do this.
the preparation paid off and the cut went just as planned.
Finished top installed with the undermount sink and faucet fixture in place.
not exactly the quickest little job, but I had fun with it.