I don't expect to use these tools to frequently probably 6-12 times a
year. In the future I hope to have more time and be able to spend more
time on projects (more tool use). I also understand that quality tools
make your life much easier (this is also true with electronic test
equipment). For tools I think my maximum budget here is $200.

Here are my possible options I thought of:
1. Use a hand saw to make the hole and use my dremel router to make
the lip (would take 8 passes per side)
2. Buy some "single use tools" (cheap tools from somewhere like harbor
freight) to do this job. Maybe an edge router and a jigsaw. I would
also have to buy a 1" straight bit from somewhere else.
3. Buy a RotoZip and attachments.
4. Buy some low-mid level tools (like Ryobi). Maybe I don't need a
plunge router.

I would like to hear from some experienced people. Maybe you have
other ways to accomplish this or know of some decent quality tools that
are inexpensive.

Nick


Ridgid has a decent combination router for about 200.00 that would be a good
place to start. Decent carbide bits aren't cheap, so figure that in also if
your budget is tight.

I presume most of your projects are small, so I would consider the jig saw a
luxury. You can rough out holes and make other small cuts just fine with
hand saws. The router could then be used to trim the rough cuts to final
dimensions.

Flip through a router book or watch some of the router shows on that
internet woodworking channel to get a better idea of how useful a router
would be.

http://www.thewoodworkingchannel.com/

-Steve