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Step 5Preparing The Sides: Part 2: Routing
The best way to cut the holes for the speaker drivers is to use a router. If you have a circle jig (like a compass for the router to cut out circles), this part is quite straight forward. I don't have one so i constructed my own jig to attach to my router.
To construct a jig:
1) Find a relatively skinny piece of wood about 3" by 10" by 0.25" (see photos).
2) Cut a hole at one end, large enough for the router bit to fit through.
3) Drill holes and find screws to fasten the wood to the bottom of the router.
4) Make sure the screws don't stick out the bottom by hollowing out the top of the holes.
On with the routing:
Next, measure the radius of your woofer. You will want a small gap between the edge of the woofer and the wood so add 1/16 of an inch or so to the measurement. This will be the radius of the first cut.
With your homemade router compass attached to the router, measure the radius: from the edge of the bit (not the center) to the point on router compass where it will revolve around. Drill a small hole at this point (on the compass) and also drill a hole on your particle board at the center of the woofer hole. Screw your router and compass to the particle board. (see pictures to clarify if all this seems confusing)
Check to make sure the router will cut in the correct location by lowering the router to the wood. Set the depth constraint on the router so it will make a cut half way though the wood. (The depth of this cut depends on your woofer). Finally we are ready to cut the wood, just turn it on, plunge and move it in a circle.
The previous cut creates the shelf on which the woofer's edge will sit upon and be screwed to. Next we have to make the actual hole. Repeat the above process except with a smaller radius and with the depth constraint set deeper, so the bit goes all the way through the wood.
Repeat all of the above for the tweeter hole. From here we will start to assemble the box.
To construct a jig:
1) Find a relatively skinny piece of wood about 3" by 10" by 0.25" (see photos).
2) Cut a hole at one end, large enough for the router bit to fit through.
3) Drill holes and find screws to fasten the wood to the bottom of the router.
4) Make sure the screws don't stick out the bottom by hollowing out the top of the holes.
On with the routing:
Next, measure the radius of your woofer. You will want a small gap between the edge of the woofer and the wood so add 1/16 of an inch or so to the measurement. This will be the radius of the first cut.
With your homemade router compass attached to the router, measure the radius: from the edge of the bit (not the center) to the point on router compass where it will revolve around. Drill a small hole at this point (on the compass) and also drill a hole on your particle board at the center of the woofer hole. Screw your router and compass to the particle board. (see pictures to clarify if all this seems confusing)
Check to make sure the router will cut in the correct location by lowering the router to the wood. Set the depth constraint on the router so it will make a cut half way though the wood. (The depth of this cut depends on your woofer). Finally we are ready to cut the wood, just turn it on, plunge and move it in a circle.
The previous cut creates the shelf on which the woofer's edge will sit upon and be screwed to. Next we have to make the actual hole. Repeat the above process except with a smaller radius and with the depth constraint set deeper, so the bit goes all the way through the wood.
Repeat all of the above for the tweeter hole. From here we will start to assemble the box.
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