When you cuts the holes for your drivers, do you make them the exact size of the inner diameter of the driver? Or do you make them a little bigger. Reason is ask is because if I make them the exact size of the inner diameter, I don't have the proper rabbeting bit size to flush mount them. So I figure I could adjust the hole size so that it works about my rabbeting bit will be the perfect size. Hope that made sense.
If you use a straight/up cut and a plunge router on some sort of jig you can dial in your flushing depth and your overall cutout diameter. Make a couple of passes at the diameter of your driver rim, until you get to the desired flush mount depth. Then reset for your cut out hole size. If your driver has a large basket you may have to do several concentric circles to get the flusmount the right width.
Originally Posted by vasyachkin
Even i, the genius, only vaguely understand what i am saying here.
Right now I don't have a plunge router and the only bits I have are a rabbiting bit set I borrowed from someone. So I need to cut the holes with my rotory tool (which I have a circle jig for) and then use my router for the flush mount. Problem is, I need to cut the holes a little larger than the driver basket so when I add the rabbit the driver will be flush with no gaps. So I guess my question is, can I make the hole a little larger than the driver basket or does it have to be the exact size? (The biggest rabbiting bit I have is 1/2 inch and by my calculation I need .66 inch for the driver I have).
If you don't do it penngray's way (which the double baffle is best for your enclosure imho) make sure if you cut the hole alittle larger that your screws have something to hit and are not to close to the edge(i have made this mistake)
Use a practice piece first as that was a good tip also. Good Luck.