Go Back   Home > Forums > >
Home Forums Rules Articles diyAudio Store Blogs Gallery Wiki Register Donations FAQ Calendar Search Today's Posts Mark Forums Read

Multi-Way Conventional loudspeakers with crossovers

Speaker construction advice?
Speaker construction advice?
Please consider donating to help us continue to serve you.

Ads on/off / Custom Title / More PMs / More album space / Advanced printing & mass image saving
Thread Tools Search this Thread
Old 6th January 2004, 01:18 AM   #1
gastro54 is offline gastro54  Thailand
diyAudio Member
gastro54's Avatar
Join Date: Nov 2003
Location: Atlanta, GA
Default Speaker construction advice?

Hey, I need to cut 3" diameter holes for my TB 871s, ( i think this is an appropriate hole size, maybe a little bigger?)

Anyways, I have been using a dremel plunge router with a circle cutout attachment I made out of some thin transparent plastic material I found around the house... The problem is that the router base occupies any space 1.5" (radius) from the actual dremel bit so I cant drill a new "pivot hole" into the circle cutout attachment I made in order to accomodate a 3" hole.

I considered buying a 3" circle cutout drill attachment from homedepot or something, but i would still have the problem of countersinking the driver.

Another problem is that the driver leads (i think this is what they're called) are too close to the mounting surround and may cause problems when used with .75" speaker construction material, in my case, MDF. So I'll have make a countersink type cut on the back of the baffle as well.

Any suggestions on how to tackle these problems?


EDIT: btw im building bipolar TL speakers with the TB 871s that planet10 suggested... if that helps
  Reply With Quote
Old 6th January 2004, 03:58 AM   #2
jewilson is offline jewilson  United States
diyAudio Member
Join Date: May 2002
Location: Plano , TX
Send a message via AIM to jewilson
Default Buy A Real Router

You need to puurchase a real "router" and a circle cutting jig. If you call Woodcraft they sale both and you'll need a sprial dual fluted carbide 1/2 shank router bit for cutting the wholes

The other method is to make a template of the speaker and use the template to cut the recess for the speaker then cut the hole.
But the guys a Woodcraft can explane this to you when you buy the router. It a got to have item for building speakers.

Don't buy power tools from home depot, they will give you poor advise. Also if you in Atlanta try Highland Hardware.
Jim W.
  Reply With Quote
Old 6th January 2004, 12:08 PM   #3
x. onasis is offline x. onasis
diyAudio Member
Join Date: Jan 2003
Location: NYS
A circle cutter like this will cut your holes. It would also make the template for cutting your shoulder cuts on the rebates (using a pattern maker's bit) with your router.

Round over the back of the driver coutout with a 3/8 to 1/2" roundover bit to let the driver breath better. Use a rattail file to cut small groves to accomodate the leads, or carefully bend them just enough to fit.

You might try to build a router table for your router as well, make it so the router with your custom base drops in from above. This makes changing bits easier. Consider a large enough base so another, larger router could be used as well.

This will give you more options for pin placement and safer control when working with smaller pieces. Do a search on router jigs, there are many great ideas out there, and be sure to read the saftey tips.
  Reply With Quote
Old 6th January 2004, 02:05 PM   #4
jewilson is offline jewilson  United States
diyAudio Member
Join Date: May 2002
Location: Plano , TX
Send a message via AIM to jewilson
Jasper makes the best circle cutting jigs

Jim W.
  Reply With Quote
Old 6th January 2004, 02:09 PM   #5
Matttcattt is offline Matttcattt  England
diyAudio Member
Matttcattt's Avatar
Join Date: Feb 2003
Location: Bristol
sorry to hijack the thread, but i need to cut a 15" hole for my subwoofer. i have a router, but i dont know how to make a jig to cut a circle. the MDF if 18mm thick (0.75" i think).
If it aint broke, don't fix it. If it is broke, fix it.
If you can't fix it, take it apart and see how it "worked".
  Reply With Quote
Old 6th January 2004, 02:25 PM   #6
jewilson is offline jewilson  United States
diyAudio Member
Join Date: May 2002
Location: Plano , TX
Send a message via AIM to jewilson

Check out this site it tell you how to make a circle cutting Jig.



Jim W.
  Reply With Quote
Old 6th January 2004, 03:19 PM   #7
Timn8ter is offline Timn8ter  United States
diyAudio Member
Timn8ter's Avatar
Join Date: Jul 2003
Location: Seattle, WA
Cut the rabbett first, 3 5/8" diameter, 1/8" depth. Then cut the hole 3". On the inside of the front baffle use a roundover bit to create a "butterfly" for air to get to the driver. This will also help get some room for the terminals. I use a Porter Cable plunge router with the Jasper circle jig. Perfect cuts every time.
Attached Images
File Type: jpg isabafflew.jpg (6.7 KB, 284 views)
  Reply With Quote
Old 6th January 2004, 08:13 PM   #8
planet10 is offline planet10  Canada
diyAudio Moderator
planet10's Avatar
Join Date: Oct 2001
Location: Victoria, BC, NA, Sol III
Speaker construction advice?
The budget method is to use the appropriate size holesaw, and then build up the front baffle with woolfelt to get them flush.

Another method is to rear mount them -- you have to put at least a 45 degree slope on the cutout.

The 871 was a development of a different driver because the distributor wanted the fancy round bezel instead of the pincusion frame... personally i'd rather have the pin-cushion.

Stay safe. Stay home. Respect the 2m bubble.
  Reply With Quote
Old 6th January 2004, 10:15 PM   #9
osey is offline osey  England
diyAudio Member
Join Date: Dec 2003
Location: Southampton
Send a message via MSN to osey
I dont want to sound too amateur, I have built many speakers in my short time on theis earth from pro audio cabs to small hifi bookshelfs, but I havent yet managed to aquire a router. (Will do very shortly though I think - I appreciate how essential they are to a good job.)

However careful measurement, a compass, and a jigsaw do work wonders. Ive made some howlers through not measuring enough/ being overconfident but the last cab I made had many circular holes (3 per cab.) I made all pretty much spot on with this method.

At the end of the day its all about practise, I make solid cabinets now, but didnt always use to!
  Reply With Quote


Speaker construction advice?Hide this!Advertise here!
Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
Speaker box construction ai60us Multi-Way 0 13th February 2009 11:43 PM
Advice for DIY ribbon tweeter construction. Puggie Planars & Exotics 3 5th May 2006 05:53 PM
Pc Speaker Construction 69stingray Multi-Way 5 16th June 2005 03:40 AM
sub construction advice paulspencer Subwoofers 5 4th November 2003 06:51 AM
Speaker construction baby_huey0 Multi-Way 12 28th February 2002 09:38 PM

New To Site? Need Help?

All times are GMT. The time now is 03:06 PM.

Search Engine Optimisation provided by DragonByte SEO (Pro) - vBulletin Mods & Addons Copyright © 2020 DragonByte Technologies Ltd.
Resources saved on this page: MySQL 15.00%
vBulletin Optimisation provided by vB Optimise (Pro) - vBulletin Mods & Addons Copyright © 2020 DragonByte Technologies Ltd.
Copyright ©1999-2020 diyAudio