How to cut holes for drivers with truncated frame - diyAudio
Go Back   Home > Forums > Design & Build > Construction Tips

Construction Tips Construction techniques and tips

Please consider donating to help us continue to serve you.

Ads on/off / Custom Title / More PMs / More album space / Advanced printing & mass image saving
Reply
 
Thread Tools Search this Thread
Old 18th February 2010, 03:29 PM   #1
diyAudio Member
 
Join Date: Feb 2009
Default How to cut holes for drivers with truncated frame

Hi all,

I would like to countersink a driver with a truncated frame (Peerless 830875), but I don't know how to do the non circular cutout in the baffle. I successfully used a hand router with a simple jig (wood and nail) for round cutouts. Filling the part is not an option.

Thanks, Ralf
  Reply With Quote
Old 18th February 2010, 03:59 PM   #2
trd1587 is offline trd1587  Canada
diyAudio Member
 
trd1587's Avatar
 
Join Date: Oct 2009
Location: Thurso, Quebec, Canada
use the jigsaw with a guide. If teh guide is not attached to the saw, make one yourself out of a straight edge that you clip to you piece you need to cut

Edit: You can use your router the way also. A straight edge on the outside off the router parrallel to your cutting.

I Hope you understand What I try to explain. I know a drawing would be better, but I suck big time at that.

Last edited by trd1587; 18th February 2010 at 04:19 PM.
  Reply With Quote
Old 18th February 2010, 07:04 PM   #3
diyAudio Member
 
smokinghot's Avatar
 
Join Date: Jan 2009
Location: Canada
Well assuming you're using more than one driver in your project, I'd suggest making a jig to guide a "flush trim bit" used in your router. Something that you'll have to design to be be easily clamped to your baffle, and have markings to ensure alignment.

Most routers can use an edge guide like this, (trd's suggestion):
http://catalog.sears.ca/wcsstore/Mas...0007_1_271.jpg

Use that guide to develop your truncated edges, and a standard circle jig for the rest.

Jigsaws are messy, and if you do develop a jig any rough cuts will be transferred to your baffle.
__________________
Jarrett
DIY addict
  Reply With Quote
Old 19th February 2010, 12:09 PM   #4
rabbitz is offline rabbitz  Australia
diyAudio Member
 
rabbitz's Avatar
 
Join Date: Jul 2003
Location: Newcastle, Australia
Make a jig and use a jig guide on the router (see pic). The jig is cut oversize and is related to the bit size and jig guide collar.

Some builders are tricky and route out the round hole but use mouldings in the vertical edges of the speaker which gives the flat surface. See this example from Andy G.
Andy G's Trinity
Attached Images
File Type: jpg HDS_jig.jpg (84.8 KB, 505 views)
__________________
No longer DIY active
  Reply With Quote
Old 19th February 2010, 12:47 PM   #5
diyAudio Member
 
Join Date: Feb 2009
Thanks for the suggestions.
So the difficult task is to make a good jig.

Ralf
  Reply With Quote
Old 19th February 2010, 12:50 PM   #6
AndrewT is offline AndrewT  Scotland
diyAudio Member
 
Join Date: Jul 2004
Location: Scottish Borders
Yes,
and the sharp corners will need hand finishing.
__________________
regards Andrew T.
  Reply With Quote
Old 20th February 2010, 11:59 AM   #7
rabbitz is offline rabbitz  Australia
diyAudio Member
 
rabbitz's Avatar
 
Join Date: Jul 2003
Location: Newcastle, Australia
Quote:
Originally Posted by giralfino View Post
Thanks for the suggestions.
So the difficult task is to make a good jig.

Ralf
It's no problem with a good jigsaw as you can cut within 0.5mm easily. I use 8mm MDF for the jig and use a 6mm or 8mm bit to do the rebate. I tend to cause more damage to the jig by sanding over the cut a bit to exuberantly.... better left as cut as the router jig guide tends to glide over any anomalies due to the larger radius.

You can use the tweeter mounting holes to locate and hold the jig but generally clamps work well. The jig just has to be large enough so the clamps are away from the router base. Cleats can also be screwed on the underside to lock on the side etc of the enclosure so there is no movement.

A test run on some scrap material is advisable but I generally just get into the enclosure.

You want to try a rebate for a Vifa D26NC with a square heatsink as it's a job from hell.

Here's some rebated HDS drivers and one also has the tweeter rebate done via a jig due to the flat edge on the faceplate.
Attached Images
File Type: jpg HDS_rebate.jpg (57.3 KB, 472 views)
File Type: jpg HDS_rebate_1.jpg (60.9 KB, 470 views)
__________________
No longer DIY active
  Reply With Quote
Old 20th February 2010, 01:04 PM   #8
trd1587 is offline trd1587  Canada
diyAudio Member
 
trd1587's Avatar
 
Join Date: Oct 2009
Location: Thurso, Quebec, Canada
Ok Next exercisse is to flush mount 'em!
  Reply With Quote
Old 20th February 2010, 04:17 PM   #9
diyAudio Member
 
Join Date: Nov 2009
Thanks guys... This thread had good timing. I am mounting a non round frame from the back with 1/4 rebate to get the tweeter/woofer distance correct for the crossover.

I just ordered a guide bushing set and will go dust of my jig saw.
  Reply With Quote
Old 21st February 2010, 03:52 AM   #10
rabbitz is offline rabbitz  Australia
diyAudio Member
 
rabbitz's Avatar
 
Join Date: Jul 2003
Location: Newcastle, Australia
Quote:
Originally Posted by trd1587 View Post
Ok Next exercisse is to flush mount 'em!
Not sure what you mean but they are rebated so they are flush mounted.... ie in line with the baffle.
__________________
No longer DIY active
  Reply With Quote

Reply


Hide this!Advertise here!
Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off


Similar Threads
Thread Thread Starter Forum Replies Last Post
Who can cut holes? smellygas Multi-Way 8 2nd August 2009 08:17 PM
What tool to cut baffle holes? kvk Full Range 24 4th April 2008 05:18 PM
8" Drivers for a small U-Frame Tenson Multi-Way 11 7th January 2007 02:27 AM
re-use DCM time frame drivers quiet Multi-Way 3 27th February 2006 03:11 AM
How to cut holes for tubes woody Tubes / Valves 23 23rd December 2004 07:24 PM


New To Site? Need Help?

All times are GMT. The time now is 06:05 PM.


vBulletin Optimisation provided by vB Optimise (Pro) - vBulletin Mods & Addons Copyright © 2014 DragonByte Technologies Ltd.
Copyright 1999-2014 diyAudio

Content Relevant URLs by vBSEO 3.3.2