Cutout Diameter

Printed From: the12volt.com
Forum Name: Car Audio
Forum Discription: Car Stereos, Amplifiers, Crossovers, Processors, Speakers, Subwoofers, etc.
URL: https://www.the12volt.com/installbay/forum_posts.asp?tid=82532
Printed Date: May 06, 2024 at 12:02 AM

Topic: Cutout Diameter

Posted By: cloak559
Subject: Cutout Diameter
Date Posted: September 06, 2006 at 12:10 AM

I built a new box for a 15" today. I had to take it to my buddies shop to cut the hole for the sub(my router broke)...He cut the hole about a 1/2" too small. Does anyone have any trick or tips for making it bigger without a router? Im pretty sure there isnt but I thought i'd ask, because his shop is a 45 minute drive tha I really dont feel like taking tomarrow morning...

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'89 Mercedes-Benz 300E
Pioneer DEH-5900UB
(2)RE Audio SX 10"s
(1)US Amps MD3D
3ft^3 @ 37Hz

Blowing up in a car accident doesnt worry me, as long as I'm putting out some major dB's when I die...

Replies:

Posted By: KarTuneMan
Date Posted: September 06, 2006 at 1:09 AM

Get out your Jig saw.....

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Posted By: aznboi3644
Date Posted: September 06, 2006 at 3:38 PM

If you have some time....hand sand it lol

Posted By: hellbass212
Date Posted: September 06, 2006 at 8:06 PM

Dremel, rotozip... I use it for alot of things so if you dont already have one I'd check into it. Shouldn't take you more than 20 minutes.

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Clarion DXZ665mp,Lanzar 2000D,2 Powerbase Extreme 12",Pioneer 5.25" - TS-C503
JL Audio e4300,Fosgate Power 6x9,5 Farad Cap,2 Optima Yellow,205 Amp Alt

Posted By: cloak559
Date Posted: September 06, 2006 at 8:34 PM

aznboi3644 wrote:

If you have some time....hand sand it lol

Exactly what I did...Took me about an hour but It dropped right in...

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'89 Mercedes-Benz 300E
Pioneer DEH-5900UB
(2)RE Audio SX 10"s
(1)US Amps MD3D
3ft^3 @ 37Hz

Blowing up in a car accident doesnt worry me, as long as I'm putting out some major dB's when I die...

Posted By: stevdart
Date Posted: September 06, 2006 at 9:22 PM

Here's how I did the same thing with my HT mains. I decided to switch out the 4.5" mids to another line and the new ones didn't quite fit into the routed holes that I made.

posted_image

You can see that the holes were mortised so that I could flush-mount the driver. That left the idea of using a jigsaw out of the question because I needed a perfect circle with the proper depth for the new mids.

I use a jig called a Jasper jig, which needs to pivot on the center of the cutout. I needed to fill the center of these holes up with solid MDF and drill a center hole so that I could rout a new cutout.

1. Cut a disk that will fit into the hole you now have.

2. Cut a backing brace that is narrow enough to fit through the existing hole, and long enough to overlap the sides of the hole.

3. Mark and predrill starter holes in the backing brace to line up with two or more of the speaker mounting holes. Then secure the backing brace to the inside of the box, extending across the cutout.

4. Place the disk into the hole and predrill starter holes that will secure it to the brace. Secure them together with wood screws.

5. Through trial (but no error), find the center of the disk by using the router and jig. Secure the jig to the center of the disk and re-rout the hole to the proper size.

Oh...I wrote all this and then I re-read your post. Oh well...

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Build the box so that it performs well in the worst case scenario and, in return, it will reward you at all times.

Posted By: stevdart
Date Posted: September 07, 2006 at 2:09 PM

My home HT main speakers, designed to flank the TV. I changed the mids to the high Vifa line, so they look better than the ones shown in these (link below). These were a buyout deal and sounded pretty good but I didn't like the metallic color and the fact that they were made to have an overlapping lip over the cutout. The new ones match the rest of the speakers better and sound better, but I haven't taken any pictures since I made the switch.

I showcased them when I got the project done HERE.

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Build the box so that it performs well in the worst case scenario and, in return, it will reward you at all times.