This is a technique for making a template for creating a cutout or recess for an arbitrary shape with just a router. This is handy for flush mounting non-circular drivers.
Tools:
1) mount the driver on a 1/4" piece of mdf/hdf with enough space around the driver to accommodate the diameter of your router base. You will use the edge of the driver as a guide for the router base, you may have to shim the driver up a bit so there is enough height to guide the router. Make sure to draw lines through opposite screw holes that will be long enough to go outside the cut out portion, these will be the guide for later alignment. Tape some paper over the driver to protect it from the dust.
2) Set the depth of the cut to go all the way through the template material. Holding the router base tight against edge of the driver to use it as a guide, route all the way around. You'll end up with a big hole, this is used as the template for the next step.
3) On a new piece of mdf/hdf, draw a set of lines at 90 degrees and line them up with the lines on the template from step 2 and clamp the pieces together. Use 1/2" material so that the final template is thick enough for the router bushing used for the next step. Put the router inside the big hole created in step 2, use it as a guide for the router base to route a cutout in the new piece. This new hole will be the template for creating the cutout for the driver.
4) Assuming you used a 1/4" router bit, use a 3/4" outside diameter router bushing to follow the template from step 3 to route the driver cutout. Again, draw lines at 90 degrees through the center of the driver location and use them to align the template.
I used this technique to do flush mounting of HiVi TN25s (square with rounded corners), it worked perfectly. Maybe it is obvious, but the minimum radius of curves/corners is the same as the router bit. Sketch it out on paper if you're not convinced it works. You can also use a smaller diameter router bit and adjust the size of the bushing appropriately.
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Tools:
Plunge router
1/4" router bit (spiral down cut recommended)
3/4" router bushing
Material:1/4" router bit (spiral down cut recommended)
3/4" router bushing
1/4" mdf
1/2" mdf
1/2" mdf
1) mount the driver on a 1/4" piece of mdf/hdf with enough space around the driver to accommodate the diameter of your router base. You will use the edge of the driver as a guide for the router base, you may have to shim the driver up a bit so there is enough height to guide the router. Make sure to draw lines through opposite screw holes that will be long enough to go outside the cut out portion, these will be the guide for later alignment. Tape some paper over the driver to protect it from the dust.
2) Set the depth of the cut to go all the way through the template material. Holding the router base tight against edge of the driver to use it as a guide, route all the way around. You'll end up with a big hole, this is used as the template for the next step.
3) On a new piece of mdf/hdf, draw a set of lines at 90 degrees and line them up with the lines on the template from step 2 and clamp the pieces together. Use 1/2" material so that the final template is thick enough for the router bushing used for the next step. Put the router inside the big hole created in step 2, use it as a guide for the router base to route a cutout in the new piece. This new hole will be the template for creating the cutout for the driver.
4) Assuming you used a 1/4" router bit, use a 3/4" outside diameter router bushing to follow the template from step 3 to route the driver cutout. Again, draw lines at 90 degrees through the center of the driver location and use them to align the template.
I used this technique to do flush mounting of HiVi TN25s (square with rounded corners), it worked perfectly. Maybe it is obvious, but the minimum radius of curves/corners is the same as the router bit. Sketch it out on paper if you're not convinced it works. You can also use a smaller diameter router bit and adjust the size of the bushing appropriately.
[wiki=Speakers:Tips And Techniques]return to Speakers:Tips And Techniques Page[/wiki]
[wiki=Main Page]return to diyAudio Wiki Main Page[/wiki]