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Old 23rd September 2012, 11:24 AM   #71
ODougbo is offline ODougbo  United States
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Join Date: Aug 2011
Location: Maryland USA
That reminds me; on a simple circle with 2 flats, go ahead cut the templete (circle) the full size. As per Bigun thought, can come back and glue 2 small pieces on the inside e.g. (| |)

Then use the router bit.

Originally Posted by Bigun View Post
It's actually pretty easy providing that the curved parts of the speaker flange lie on the same circle. In other words, if there were no 'flat parts' the outer flange would be a circle, like most other drivers.

You will use a regular router with a guide (you can DIY your own guide) for making circular cut-outs.

Draw the circle in pencil first (use a compass, or make a compass) which has the same diameter as the curved part of the driver flange. and mark the points where the driver cut out changes from an arc to a straight chord.

Route the circular arcs, stopping before you cut into the wood where the shape changes to a straight chord. You will need to route several concentric circular arcs so as to remove all the wood from underneath the curved part of the flange, back to where the hole through the baffle will go.

Then clamp a piece of straight edged wood to guide the router for the straight sections of the flange and route those - joining the already routed circular arcs. You may need to move the wooden guide towards the centre of the circle and cut parallel lines until you've removed all the wood from where the flange will go.

Then route the hole in the baffle that the driver will sit inside, being careful at the last cut because this will usually 'free up' the centre anchor point your are rotating your router guide around.

I did it this way for my AN 15" driver: A Big'un - the Audio Nirvana Super 15

posts 76, 205, show some images but not the method and the 'flat' bits were relatively small but the method should work for any sized flat bit.
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Old 25th September 2012, 10:29 AM   #72
ODougbo is offline ODougbo  United States
diyAudio Member
Join Date: Aug 2011
Location: Maryland USA
Pic... for last post #71

btw, see the tabs in the top corners, had to cut that for the clamps because the box was small; the clamps fit right in there.
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Last edited by ODougbo; 25th September 2012 at 10:48 AM.
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