Adapter for Smaller Driver in Existing Hole

[justinzane]

I've got a 12" driver that I want to put in an existing enclosure with a 12" ID hole. Of course, the driver needs an 11" dia. hole and will just about slide through the existing one. Is there any alternative to making a new face for the box with a new sheet of MDF?

I'd love some sort of adapter, but I can't figure out a sufficiently strong way to make one without a serious woodshop -- that I do not have. 🙁 Premade products that cost less than a new sheet of MDF and labor might be considered.

Thanks!

 

[gmphadte]

Take a thicker square piece of plywood and make a step, make the hole sized for the driver and thin the plywood with a round ring thick to go in the bigger hole. Nut bolt it to the mdf.

Gajanan Phadte

 

[dangus]

Temporarily screw a scrap piece of plywood or MDF across the opening from the inside. Screw another piece to it to create a surface that's flush with the baffle. Locate and drill the center. Use a router to enlarge the cutout to clear the new driver. Get two pieces of MDF, clamp or screw them so they're side by side. Cut the new driver opening in this panel. Trim it so it will fit on the backside of the old baffle. Screw and glue or clamp and glue it in place.

 

[justinzane]

Thanks for the answers guys. I think I will go for the plug and cover approach. Like so... [C = MDF Cover, P = MDF Plug, D = Driver, # = Existing]

###
I.#
n.#C
s.PC
i..D
d..D
e.PC
B.#C
o.#
x##

Since this is a LF driver, there should not be any significance to the shape or edge profile [sharp/round] of the cover since all the wavelengths are vastly longer than 0.75", correct?

 

[Pano]

Correct. I've done the plug 'n patch, too. It's some labor, but it works well.

 

[planet10]

An example of one that Bernie did.

A bit more meat to work with than you have -- nominal 6.5 to 4"

Before:

dave

 

[justinzane]

@planet10: those are ******* beautiful! I know some guys who have that kind of vision and skill, but I'm not one of them. A nice lacquer job is about as far as I'd go. Thanks.

 

[planet10]

All Bernies's work (i did the design & the drivers)

dave

 

[JMFahey]

Beautiful cabinets.
Congratulations.

 

[sreten]

Hi,

You could :

Cut out the correct sized hole in a square of mdf.

Then cut into 2 pieces,
(assuming the rear and baffle are non-removable).

Screw and glue them to the inside of the cutout.

Front mount the driver in the existing cutout.

rgds, sreten.

 

[justinzane]

@sreten: simple, excellent idea!

 

[justinzane]

One thing I thought about is using casting resin to create a plug. Seems like this could create a strong bond without changing the inside or outside dimensions of the enclosure. Anyone use cast resin as part of an enclosure?