Cyburgs-Needle for Tangband W3-871S

[Mike514ml]

Very nice Mod_Sonic.

I did something similar, but since I didn't have a router, I used a variable speed electric drill with a 1 1/2 inch (38mm) sanding drum - 60 grit IIRC. It's faster than a Dremel, but you have to be careful when you get down to the last 1/4 inch (6mm) or less. MDF just melts away with 60 grit at full speed .

If you're using an Aura Sound or Hi Vi driver with a square frame, you might be able to do a full circle relief instead of a 'clover leaf' since they have a larger mounting circle (90,93mm) than the Tang Band (84.5mm).

Mike.

[mod_sonic]

Hi Mike,

I think I've spent as much time so far making bits from scrap timber and MDF to make a better job of making the Needles as I have assembling the Needles themselves. Bits include :

- a router compass to cut the speaker holes and recess
- temporary extensions for the guide bearing when trimming the sides and tops
- an offset router base on which I rest a weight to stop the router tipping when I'm trimming using the guide base

How did you manage to make the speakers without a router ?!

Mark

[greenie512]

Mike - don't know if you've got one but I wouldn't be without my Jasper jig for cutting driver openings.

I packed up yesterday totally "routered out" - see WIP shots http://www.greenie512.net/greenie512...ges/HT8-20.jpg (this ones not a full ranger)

[Mike514ml]

Mod_Sonic,

I used an adjustable hole saw to cut the driver openings - it wobbles, but if you let the mdf wobble with it, the holes come out round and the right size.

I'm using a double terminal block for the connectors, so all I had to do there was drill holes.

I've gotten a nice little Wilton router at a local home improvement store, and used it to do a 1/2 inch (12mm) round over on the edges, but haven't tried doing any compass work with it yet.

I've got a Dremel too. In the future, I may try using it with the router attachment for small diameter (3 inch) holes .

Mike.

[gychang]

Originally posted by greenie512
Mike - don't know if you've got one but I wouldn't be without my Jasper jig for cutting driver openings.

I packed up yesterday totally "routered out" - see WIP shots http://www.greenie512.net/greenie512...ges/HT8-20.jpg (this ones not a full ranger)

tried to resist buying the jig but jig saw is not good for perfect circles in my hands. I have Hitachi router, hope it fits.

gychang

[greenie512]

Originally posted by gychang
tried to resist buying the jig but jig saw is not good for perfect circles in my hands. I have Hitachi router, hope it fits.

gychang

Yep - for the life of me I can not cut any where near even a slightly accurate line with a jig saw. Jasper come with loads of fixing holes for various routers. If yours isn't one of them - with a bit of care - you can drill fixing holes. It comes with a centring plate - so that should help.

[AdamThorne]

I was somewhat suprised that I managed to get speaker mounting holes cut with a jig saw. Not that the lines look particularly nice, but the driver fits.

The dremel opened up breathing space for the driver quickly and easily, with the sanding drum. The MDF didn't put up much of a fight, I imagine plywood might have been a bit tougher.

I'm torn between trying to get a real router or the router attachments for the dremel. If you get (or already have) the dremel-router lemme know what you think.

-A

[gychang]

Originally posted by AdamThorne
I was somewhat suprised that I managed to get speaker mounting holes cut with a jig saw. Not that the lines look particularly nice, but the driver fits.

I'm torn between trying to get a real router or the router attachments for the dremel. If you get (or already have) the dremel-router lemme know what you think.

-A

I don't have a dremel, but my impression is on a plywood, does not work, since the project is too large.

I finally gave in and bought router and jasper jig, jig is on its way.

gychang

[zobsky]

Originally posted by AdamThorne

I'm torn between trying to get a real router or the router attachments for the dremel. If you get (or already have) the dremel-router lemme know what you think.

-A

I have a dremel router attachment, .. it works okay but a bit of a pain to use, . .mostly because the dremel is underpowered for this kind of work and takes a long time to eat away wood stock. I prefer my plunge router 1000% over.

[bzdang]

Hole saws are available in sizes suited to make the speaker mounting hole, are inexpensive and safe to use.

Start the hole from the front, go half-way through, and complete the hole from the opposite side. Be patient (slow rpm, don't overheat the tool) and clear the sawdust very frequently (every few seconds).

A coarse round file works well to open up the back side of the hole and it is easy to leave wood where the mounting screws go. Drill a golf ball to make a file handle.