So I now have one baffle drilled, and I used a router to make the baffle match the back and sides, figuring it would be easier than the 63* jig, and circular saw with 27* bevel.
I was wrong as I have major chip out, but being the first time ever using a router, maybe I did it wrong, or used the wrong bit? (1/2' straight bit)
ANyway I found the router base was hitting the back/side to be trimmed as I slid it along the spacer board. I went on an angle and found the router skipped. I theory it works, and it DID work out but with chipping. I figure a router should not be that difficult to use.
I used a fixed base, so maybe I need a plunge?
Here is how it was set up:
http://img197.imageshack.us/img197/1082/dscf2747m.jpg
As you can see the base hits the piece I want to trim and the router stops.
This was the end result:
http://img231.imageshack.us/img231/9082/dscf2750.jpg
I dont think this is how it is supposed to be done:
http://img218.imageshack.us/img218/4439/dscf2743p.jpg
Before the slaughter:
http://img87.imageshack.us/img87/8046/dscf2737.jpg
For the next speaker box i think i will go back to the jig, and my 27* sled I made. Much easier, and cleaner cut.
I know I didnt do something properly. Maybe you can point out what went wrong?
I will just fix up the edges best I can and either paint a flat black, or cover with grill cloth.
Or I can re do another baffle as this one has the grain the wrong way.