Best way to cut a speaker hole in a baffle?

[billkatz]

On my omni I did it freehand with a jigsaw, and the hole was functional, but not pretty. Is a router with some sort of circle jig a better option? Do you need to lock both the inner (waste) and outer (baffle) parts to a base to keep things stable at the end of the cut?

I know there's some good experience out there...

[sine143]

if you're keen with a router, its the way to go (proper jigs available of course).

a jigsaw is a passable way to do it though. just take your time.

[DJPhatman]

If you already have a router, you should be using it with a circle jig to make all but the smallest holes. Forum member "AntonZ" even made his own circle cutting jig. Don't forget to take into account the cutting diameter of the router when building and using the circle jig.

[Oxonjohn]

Just done my first baffle holes with a router and home made jig (see http://billfitzmaurice.info/forum/viewt ... 3&start=15). Piece of cake and a pretty good result.

[miked]

There is no more accurate and easy way to cut a large hole in a piece of wood, then using a router. Whether you use premade hole-jig like the Jasper jig (I do) or a homemade jig, it makes no difference. The hole will be perfectly round and properly sized.

In the distant past I have cut with a jigsaw and then hand-sanded to size/shape. Took forever and still looked poor. I have cut with a jigsaw and then used a spindle sander to finish to size/shape. Was faster but still not totally round. I guess it depends on your woodworking skill level. I know different ways to reach a result, but my "finesse" is lacking. I'm the "Kill the fly with the bazooka" guy. For ME, it's best to just use a router. No real finesse involved there, and it's fast.

[jswingchun]

There is no more accurate and easy way to cut a large hole in a piece of wood, then using a router. Whether you use premade hole-jig like the Jasper jig (I do) or a homemade jig, it makes no difference. The hole will be perfectly round and properly sized.

+1 to the Jasper Jig. Not that expensive, worth every penny.

[AntonZ]

If you already have a router, you should be using it with a circle jig to make all but the smallest holes. Forum member "AntonZ" even made his own circle cutting jig. Don't forget to take into account the cutting diameter of the router when building and using the circle jig.

Here it is: http://billfitzmaurice.info/forum/viewt ... 91#p204291

[koturban]

On my omni I did it freehand with a jigsaw, and the hole was functional, but not pretty. Is a router with some sort of circle jig a better option? Do you need to lock both the inner (waste) and outer (baffle) parts to a base to keep things stable at the end of the cut?

I know there's some good experience out there...

Router and circle jig is easiest.

I secure the waste down onto a scrap piece of plywood (or whatever) with two screws anywhere but in dead center, where the jig will go. Don't forget to drive the screws below flush.

You can clamp the baffle down to the workbench but make sure they don't obstruct the path of the router and jig.

Don't try to make the hole in one pass. A few is better.

If you are doing more than one baffle, you can stack the pieces and make both holes at once.

Check the first post here for a pic of my circle jig setup.

http://billfitzmaurice.info/forum/viewtopic.php?t=17442

[Fastskiguy]

I was gonna buy a hole saw and bust out the drill for my SLA project….that'll work OK, won't it? Assuming smallish holes….

Joe

[DJPhatman]

I was gonna buy a hole saw and bust out the drill for my SLA project….that'll work OK, won't it? Assuming smallish holes….

Joe

Yes, just be sure to use a low speed drill press. My SLAs will be done with a 4" hole saw, and I plan on drilling 1/2" sawdust escape holes to help with cooling the saw teeth.

[88h88]

My circle drawing jig/router jig. The one that came with the router is huuuuuuuuuuuuuuuuuuuuuuuuuuuuuge. This is a few wood scraps and a couple of spare cross braces from the shelves in the garage.




Does it work well? You tell me.