Speaker Finishing - Aluminum Trim

[Narcisse91]

I am building a pair of Dave Brown's dB616TLs.
http://users.d-web.com/dbrown/db616tl2/db616tl2.htm

They are pretty much completely built, I just need to attach the bases to the speaker cabinet.

I'm debating how to finish them. My latest thought is flat black paint over the entire thing with three pieces of aluminum trim - one on the top of the base, one on the lower front (small plaque with a graphic, name of the speaker, something like that) and one on the top, a three ring piece that will be a bezel around all three speakers. It will be one piece.

I drew up the three ring piece with the software from http://www.emachineshop.com, and it would cost about $125 each. I think the rest of the speaker - drivers, crossovers and materials - only cost about $150 to $175, so I hate to spend that much.

So my question to you all is this: How would I go about making this piece at home? If you can't picture it, it is like the Audi logo, except with three circles, and the center one would be smaller. It wouldn't have to be thick aluminum. Realistically, the thinner, the better (cheaper, easier to work with). My ultimate goal would be to finish it giving it a brushed aluminum look.

I can make a template out of hardboard without a problem. I've got a jig saw, a (fairly simple, and well-aged) router, a Dremel 400 series, jasper jigs, and some attachments for the Dremel. I'm not opposed to buying bits or attachments.

I've also got fairly steady hands, a lot of patience, and plenty of time (since I can't paint them until it warms up enough for me to haul them out into the driveway).

Can anyone offer any pointers? Can I do this with the dremel or the router? What bits would I need?

I also considered doing stainless steel and polishing it to a mirror finish, which I think would look pretty neat, but the stainless should be even harder to work with, I would think.

Thanks for the help.

[Narcisse91]

So, 130+ views and no responses means I'm probably trying to do the improbable.

I decided that maybe I would just get a rectangular piece of aluminum with three holes cut out - something Front Panel Express can do. In the process of creating a new drawing, however, I noticed you can set the rounded corners pretty large - in this case, 3.625 inches. Basically, it creates an oval-like shape with a long straight center section. The cost is under $50 each. I can probably live with that.

I'm still open to ideas if anyone comes up with anything.

[Aengus]

Hi Narcisse91

130+ views and no responses means I'm probably trying to do the improbable

Maybe, or maybe nobody as foolhardy as me saw it yet

If you have a router with a flush-trim or a template bit (with bearing below or above the cutter, respectively, to guide it) you can use your hardboard template to guide the bit. If the aluminum is thin, you should probably also clamp it between sheets of sacrificial plywood or MDF - so you have a sandwich with layers of MDF/Aluminum/MDF/template.

If your router has variable speeds, slow it down some; and use a carbide bit. Aluminum works pretty much like wood, just be careful and clamp things down well since cutting tools tend to grab it.

Good luck, and post pictures of what you end up with.

Regards.

Aengus

[Narcisse91]

Unforunately, my router is not adjustable, but I think I have access to one that is. So a good carbide bit will do fine with the aluminum? That was one of my concerns, along with that even a router on slow will go to fast to cleanly cut metal.

[Theli]

a good quality carbide bit will do fine, as for speeds on the cnc router we have here at work (to cut aluminum) spins at 18000-22000rpm and cuts at about 100inches per minute. Wear eye protection and full length clothes, the aluminum chips can get very hot. I hope this helps.

[Narcisse91]

I'll have to see if I can figure out what speed my router actually goes...

Are we talking a solid carbide bit? I did some web searching, and I can't find solid carbide bits with bearings on them. Plenty of carbide tipped...


EDIT: Actually, all my bits are carbide tipped...

[kec]

I've done small round overs on 1/4" aluminum plate using my Porter-Cable trimming router (w/no speed adjustment) and carbide bits. Works good. Just be very careful.


-Ken

[gfinlayson]

Carbide tipped bits are fine.

[kec]

Originally posted by Narcisse91
Are we talking a solid carbide bit? I did some web searching, and I can't find solid carbide bits with bearings on them. Plenty of carbide tipped...

Solid tipped.

[Narcisse91]

Ok. Is there any real difference between the $25 bits at Home Depot compared to the $75 bits at a woodworking store? Is it worth picking up a new bit for this?

I'm concerned with the width of the rings (I was thinking 3/8"), if I don't get a really smooth cut, I'm afraid one hard kick could ruin the aluminum. Even if I sandwich it between MDF, I think it will still be a problem, particularly near the end.