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Old 27th March 2004, 11:30 PM   #1
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Default Best hole cutting method?

What is the best method for cutting the holes for speakers? I have seen the router templates that Parts Express sells. Just not sure how they will work.

I will be flush mounting them as well. So I assume once the hole is cut, I will use a rabbit bit on my router to allow the flush mount.

I looked at using a jigsaw, but it's impossible to get a clean cut.

What's the preferred method?
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Old 27th March 2004, 11:36 PM   #2
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I have a circle cutting jig I bought at Sears for about $20. I'm pretty happy with it. It doesn't have any measures on it like the jig PE sells, but I'm not sure I'd trust the jig's measures anyway.
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Old 27th March 2004, 11:40 PM   #3
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Is it used with a router?

If so, what type of bit do you use?
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Old 27th March 2004, 11:50 PM   #4
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DIY circle cutting jig:
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File Type: jpg circjig.jpg (37.4 KB, 951 views)
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Old 28th March 2004, 12:36 AM   #5
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SB,

IMHO the router should always be the first choice for circles.
I use the plastic Sears jig and it's fine.

For recessed driver mounting, I first cut the larger recessed part, to full depth on both speakers, It usually takes a couple of passes to get the width that you need, I do equivalent cuts on both speakers before changing adjustments.- a pain , but keeps the sizes consisitant. T I reduce the diameter more to the hole size I want and run a circle, increase the depth ,then run another circle until I'm through About 1/4" is as deep as I go on a cut.
I use a bit that makes a flat bottomed groove. Get Carbide bits
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Old 28th March 2004, 01:28 AM   #6
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I tried a jig saw to cut a hole a few times & the best I could ever do was barely fair. Mostly they looked like my dog gnawed the holes for me. Router is the only way to go IMO.

I spent the $30.00 on this jig, and it is well worth it. You do have to drill holes in it to match up with the holes on your router.

http://woodworker.com/cgi-bin/FULLPR...0&LARGEVIEW=ON

You can make the same jig out of a $6.00 piece of acrylic from Home Depot, but cutting the recessed slot on the bottom just wasn't worth the effort for me. The nice thing about a jig with a slot though is that you can set it to the precise hole size you need.
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Old 28th March 2004, 01:31 AM   #7
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Also the size matters. If I can I always use hole saws. But those only usually go up to 4"-4.5". But these are the most convenient and precise for me.

For stuff like woofers, I usually use a compass and draw the circle, and then use a hand scroll saw. Always works for me.

However I don't have a house yet, so I'm limited to hand tools. The ways described above using the routers are much better. Except for the small holes, I still think hole saws are the best method (for standard round holes that is).
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Old 28th March 2004, 02:08 AM   #8
Variac is offline Variac  United States
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I have a 4" hole saw. I tried to cut my 15" woofer opening with a jig saw. Try a router and you never go back!!
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Old 28th March 2004, 02:29 AM   #9
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I think the router with a circle cutting jig is by far the best way to go. Doesn't matter if it is homemade with a piece of masonite and a pin or a Jasper Jig which for the person who was cautious about it's accuracy is dead on accurate.
Unfortunatley not every has a router and the thought of spending any more money on tools to make a set of speakers (especially a 150 router plus 20 1/4 straight bit plus the 30 jig) causes me strain these days.

Here is an option that you can do with a jig saw. Take any strong 1/4 inch material (masonite, luan, etc) that is bigger by about 4 inches over the radius of you circle to be cut and hotmelt glue it to the bottom of your jigsaw foot. Now take your 1/4 inch drill bit and drill a hole the radius of your speaker cutout away from the outside edge of the blade. Grab a 1/4 dowel or pin and drill a hole at speaker center and you are ready to make a pretty clean cut. You will need to drill a pilot hole for the jig saw blade as well and be very careful as you come around to where you started but I think you will be very satisfied with the hole.
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Old 28th March 2004, 03:13 AM   #10
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For this
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non circular hole is used

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