tweeter rabbet too small, enlarge hole methods?

[Jared]

So I cut the hole for these about a decade ago and then went to use the rabbit router bit to flush mount the tweeter and ran into the diameter being 1/8" too small. I dealt with a similar situation for maybe 1/32 to 1/16" (maybe 1-2mm) and stapled some sand paper to a circle blank from routing pout the hole and made a temporary drum sander. This wont quite work for this I am afraid.

Anyone know how to enlarge the rabbet part? the only way I can think of is to glue in a blank and route it out again... I would rather buy a tool though lol. I already got the adjustable rabbet and it is as big as it goes ( smallest bearing)

 

[phivates]

Stupid rabbet sets don't get that we need a bigger step than 1/2". They're stupid.

 

[Jared]

Stupid rabbet sets don't get that we need a bigger step than 1/2". They're stupid.

such true words.

 

[phivates]

CMT had a tenon cutting set that would maybe work but it was expensive. You get to do it the clunky way. Stupid. Give us 3/4s!

 

[phivates]

CMT tenoning router bit set is $138 and is designed to go 1 1/16. Not quite right either.

 

[Hoo19]

Rabbet bit bearing

Can you change the bearing on your router bit to give it a deeper bite? I have been successful with a smaller bearing in a similar situation, so much so I bought an assortment of bearings from McMaster Carr to give me different rabbeting depths.

 

[Michael Bean]

I was faced with a similar situation a few years ago. I first made a temporary plug for the hole, then used my home made circle jig. It worked like a charm.

Mike

 

[fatmarley]

Make the correct sized hole in a piece of mdf (or whatever), place on top of your smaller, wrong sized hole and use a template bit to router out the existing hole to the correct diameter.

 

[Soldermizer]

Ooooh, dat scrwoowy rabbet!

 

[Tromperie]

I was faced with a similar situation a few years ago. I first made a temporary plug for the hole, then used my home made circle jig. It worked like a charm.

I did this too.

 

[puppet]

Couple ways out. Round base router? Make a templet that the edge of the base can ride against ... ie. piece of mdf large enough for the correct tweeter hole dia. plus half the router base measured to the mortise style bit you'll be using. Base of your router will ride on the baffle you have pictured.


Another alternative is to scribe the edge of the tweeter on to the baffle while it's setting in the hole. Sharp knife should do fine. Remove the tweeter and route to the scribe line freehand. Again, you'll be using a mortise style bit.


I'd go for the first option.

 

[Andersonix]

Anyone know how to enlarge the rabbet part? the only way I can think of is to glue in a blank and route it out again...

You can screw in a piece that spans the opening from behind the baffle, and then attach another piece to it, in which you drill a new center hole for using your hole cutter attachment to enlarge the counterbore.

 

[Pano]

^ I've had to do that. Was a bit difficult getting the center again. Maybe there is a trick?

 

[phivates]

If you have the hole saw that made the original opening you can use it to locate the center after placing a temporary support inside the box. Disclaimer: I am an old car audio guy with just about every hole saw and arbor there ever was.

 

[russc]

^ I've had to do that. Was a bit difficult getting the center again. Maybe there is a trick?

If you enlarge the screw holes in the cross piece & use a large washer under the screw head you can fine tune the position if your initial drilling is a bit off.