Driver clearance

Hello, I want to surface mount some drivers that are mounted in the inside of the box (ND90). I don't have a router so I can't flange the buffle (except maybe by using a file) this is why I thought of surface mounting. But The plywood is thick and it does leave any space in the inside for the driver to "breath" especially given the way this particular driver basket is shaped. Should I try and file a little bit of the inside to give more room around the basket. Should I try and flange the baffle by hand? Should I not worry about it?
 
This is how it looks in the inside of the box.
 

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First, let me say one thing: if you want to build speakers buy a router, especially if you plan to do it more than once. Even a cheap router will ease your work, and will help in making things that without one are impossible or really hard to perform.
Having said that, looking at the datasheet, the flange appears to be 1.5mm thick, so the ND90 is likely designed to be (also) surface mounted.
What you need to do is to scallop/chamfer the rear of the baffle to permit the driver to breathe. See here: chamfering driver holes Your case seems likely the case B in the above link, and needs to be transformed into C.

Ralf
 
Please find attached a pic of a "chamfer" on the inside of a driver cut-out.

This particular one was done by a router, but you can do something similar with a rasp (pic attached) and sandpaper.
 

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If you have a hand jigsaw you could use the angle setting on the foot to add a chamfer of sorts between the screw holes. Another option is to use 2 thinner pieces of ply for the baffle and make the rear piece with a larger cutout than the front piece to give some breathing space.

Cheers,
Rob.
 
Thank you all for your help. I guess I will try doing it with the rasp. Would using a forster bit all around the hole diameter be a good idea? Moreover should how much should I do this? To the point I completely clear the wood around the "vents" of the driver's basket or that's not necessary?
 
Kyrk,

Please refer to the pic below (collected from the Internet) - it shows the thickness of the inside edges; you can try to make it like this or slightly thinner as you have a smaller driver.
 

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Decorelation of reflected wave in frequency range that we are most sensible. That won't say you don't need damping but less of it which can be benificial ( for liveness of reproduction).

Nice result you have.
 
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