What is simplest way to route speaker baffles?

[protos]

I am in process of building my first (serious) set of speakers in a woodworking class.I was wondering if there wasn't a simpler way of routing speaker baffles than making larger template-guides for the router to follow around. I mean you have to make a precise template then clamp this precisely centered on the baffle etc etc.

[jackinnj]

there is a circle cutting jig -- fits onto the router and at the center of the circle -- just adjust for the radius you want -- don't cut all the way through, however -- you want to leave a little bit of the veneer at the bottom of the cut so that the center stays in the center as you finish the cut. when done just knock out the circle. i am pretty sure that these are carried at Home Depot and Woodworker's Warehouse (you must have some DIY superstores in Ireland, don't you?).

there are chamfer router bits with a ball bearing edge guide which allow you to put a bevelled edge on the cut.

if you are just making one set of speakers, ordinary steel bits are OK but the investment in carbide bits is well worth it if you are going to do a lot of routing or cabinet work.

[rabbitz]

Jasper Jig is what you need. Look up the thread

Jasper jig and metabo routers

[protos]

Yes I think I have seen those. But what if the radius of the circle is less or equal to the radius of the bit to the outside edge of the router?A lot of routers seem to have like an 6/7inch diameter. How do you cut or rebate holes for smaller mid/woofers and tweeters? Does the jig allow for that?

[jackinnj]

I use a sabre saw for the smaller holes -- it's not as acurate as the router on the circle jig--

you can also make a big circle out of some scrap plywood, just do the math -- you will need clamps, however.

[jbateman]

Originally posted by protos
Yes I think I have seen those. But what if the radius of the circle is less or equal to the radius of the bit to the outside edge of the router?A lot of routers seem to have like an 6/7inch diameter. How do you cut or rebate holes for smaller mid/woofers and tweeters? Does the jig allow for that?

The Jasper model 400 allows you to cut circles from about 1 inch up to 7 inches.

[JOE DIRT®]

a Hole saw always works well for small diameter holes...I keep up to 6" dia. in my tool box.....anything larger than that then a circle bore jig cutter is what I use

[Vikash]

You can always make a jig like I did... - A nail in a strip of wood bolted to the router.

you want to leave a little bit of the veneer at the bottom of the cut so that the center stays in the center as you finish the cut.

Good advice (I always learn the hard way!), and if you're flush mounting the driver, then I would also advise cutting the recess first.