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Old 29th March 2008, 11:14 AM   #1
kvk is offline kvk  United States
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Default What tool for Cutter baffle holes

I supposed a Jasper Jig is probably the best tool for routing baffle holes for drivers but it's about $40 which is a fair amount if you are only building one pair of speakers.

Are there any cheaper options? Does someone make something like a cheapo adjustable jig for routers?

I do have a router and bits already.
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Old 29th March 2008, 11:45 AM   #2
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Drill a lot of holes in a circle............
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Old 29th March 2008, 11:53 AM   #3
EC8010 is offline EC8010  United Kingdom
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Default Re: What tool for Cutter baffle holes

Originally posted by kvk
Does someone make something like a cheapo adjustable jig for routers?

I do have a router and bits already.
Last Wednesday I made a trammel for my router and cut two perfect circular holes with rebates in plywood without any splintering. All you need is a strip of something reasonably rigid (I used 1/4" SRBP, but you could use aluminium). You screw the router to it, and at the right distance from the cutter, you drill a hole for a bolt to go through the centre of the circle you want, drill a hole that size in your baffle. Then, with great trepidation you gently lower the bolt into the hole in the baffle, switch the router on, and cut a perfect circle.
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Old 29th March 2008, 03:48 PM   #4
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Try using the shank (blunt) end of the drill bit as a pivot rather than a bolt, it will be a tighter fit and wont allow any "wander" whilst cutting.
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Old 29th March 2008, 04:09 PM   #5
cuibono is offline cuibono  United States
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I do the same as the above two. Not perfect, but decent.
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Old 29th March 2008, 07:27 PM   #6
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If you are doing anything over 5" the above methods work well.

Hole saws are available up to 5".

What makes the Jasper work is that the center pin goes into
a metal shank and so the router will not pull out of round.

Using a circle cutter with just a pin through wood has not worked very well for me.

Other method not discussed yet is the jig saw with circle jig.
the circle jig attaches and goes for about $7 USD here.
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Old 29th March 2008, 10:19 PM   #7
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I used the Jasper last weekend for the first time, and the ease and accuracy of the cut pays foir itself with just the four holes and rebates. Anything new I do is just going to be a bonus, I reckon.

I dunno why I tried all those other methds beforehand - the wastage of wood and time seems like such a silly thing to have gone through.
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Old 29th March 2008, 10:40 PM   #8
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As I recall Jasper had some complicated calculation to do circles.

Did you center and eyeball the right calibrated hole or use the
Jasper system?

BTW, Jaspers go on deal once in a while and as a set with a larger and smaller one.

I have some better bits now so I may give my small roto tool a whirl at doing circles with it's kit again. The pin in that rig fits snugly into a
certain gauge of T-nut. But I'm still using 4 in speaks so never did a finished circle cut with that rig.
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Old 30th March 2008, 02:59 AM   #9
Nanook is offline Nanook  Canada
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Default her's something pretty interesting..

jobmate cutout tool

Haven't tried it, but my cohort just bought one, will try it out on some small OB speakers.

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Old 30th March 2008, 10:47 AM   #10
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I've used this for the last 5 years with no problems at all. Pic shows the jig upside down. Its best used if the target piece is placed ontop of a piece of scrap so you can drill the centre of required hole thru both pieces.

for duplicating holes I find it much easier to cut a template with the jig tool and then just used the template.

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