So I just totally botched up my latest little creation. I finally went and got the Sears router jig that Zaph recommends, having cut every previous driver hole with a jigsaw up until now. In the past when I have tried to cut a hole in a baffle that is 1.5" thick, the blade kinda bends without me realizing until after the hole is completely cut, and I have to go around trimming the inside of the hole to make it so the driver can fit, which of course makes for a messy backside of the baffle for hurricane nuts and things to grab onto. I got the router guide and a router bit I assumed (mistake #1) would do the job fine. It was only barely long enough (just over 1.5") to make the cut, but still seemed to cover the thickness of the baffle. To make a long story short, my shop is absolutely THICK with smoke right now. The bit always seemed to be having trouble with the cut, and I had to put alot of pressure on the router to make it move, to the point where I accidentally, without realizing it, slowly extended the dimension of the cut so that when I got around to the beginning of my cut, I was about 1/2" further from center than I started. This is obviously not good, and I am scared to try again without more info. I even experimented and retracted the bit up so only about an inch was into the wood, just to make sure i wasn't forcing a part of the bit that wasn't supposed to be cutting, but it didn't change much at all. Is there some special kind of bit I should be using? Should it be that hard to move it during the cut? Does anybody know of a hole-saw set that goes from 15" down to 3" in 1/4" increments in case I never get this? Any tips from the router-jig-experienced would be GREATLY appreciated.