(I know I'm writing a lot of detail into my build threads, but I figure that someone might point out a better way to do some of it, and that it could be useful to someone else who is just getting started -- kinda like me a few weeks ago.
I've been thinking about how I want to cut the hole for the waveguide. I'm not trying to find the easiest way to do it, but rather some way that lets me try a new technique with my tools.
I realized that my original idea of using a top-bearing flush trim bit
with a template is not a very good one, since the baffle is 3/4" thick. I'd have to either make a very thick template or cut all 3/4" in one cut so that the bearing could ride on the template. So I scrapped that idea.
My next idea was to use a guide on the router with a template. I bought the Bosch guides
that work with my router. And I have a 1/4" up spiral bit
. So I figured that I would use the 1/2" OD guide, which means that I would add 1/4" to the dimensions of the waveguide cutout when making my template.
So I grabbed a spare piece of 1/2" Arauco plywood and started making my template. It seems like people always say to use a circular saw for stuff like this -- driver access panels, etc. So after I drew out the lines for my template, I grabbed my circular saw. My circular saw is setup with the base for the EZ track
so I grabbed the track and lined it up on my template. In this case, I didn't really use the track edge directly since I wanted to clamp on the other side of the cut. But the edge was still useful as a reference -- I just clamped the track 1/8" or so away from the line and kept the edge parallel with the line.
To get the saw ready, I retracted the blade since I would be plunging into the surface rather than cutting from an edge. I also removed the zero-clearance insert from the EZ saw base, since it was blocking my view of the cut on the front edge. I setup a bright work light, too, so I could really see where I was cutting.
Once everything was lined up, I loosened the plunge lock on the saw, started the saw out of the wood, and then slowly plunged the blade into the wood. I then moved the saw forward and back almost to the lines that marked the ends of the cut. I lifted the blade out of the wood and then let go of the trigger. I did the whole cut with the plunge lock loose. I don't know if that is the right way to do it, but it seemed to work fine. Then I did the same for the other three sides.
To complete the template, I used my jig saw to cut out the wood that remained at the corners -- the stuff you can't cut with the circular saw. It came out pretty good. However, I did chip the wood in two of the corners by stupidly lifting the jigsaw away before the blade had completely stopped. You would think that I would have learned after chipping the first corner, but I guess it takes me two times before it sinks in.