Originally Posted by Erich H
I'm not sure I follow what you mean here.
There will be 2 baffles, the inner one will drop into rabbets that are cut in the side panels. So the inner baffle will be completely flush with the sides, top, and bottom. The circle will be cut so the driver mounts to that inner baffle.
The outer baffle will be cut a little bigger than the overall woofer diameter. Then it will be placed on top like all other speaker baffles usually are.
Basically the driver will be recessed .75" on a 1.5" thick baffle.
The only issue I'm seeing is that overall dimensions vary a decent amount. So I should probably shoot for the largest one. But sometimes that might mean the outer baffle is .5" bigger than the driver....leaving a .25" gap all the way around. I doubt that would be an issue if it was given a roundover.
But if I don't do that, then every outer baffle would need to be cut for each specific driver. You can imagine how crazy that could get......these are just "general" boxes for people to use.
Example with the 10" drivers:
Dayton RS is 10.5" overall.
Titanic is 11.02"
LMS is 11"
So the outer panel should be made to 11.02". But will the Dayton look okay? The difference is due to the Dayton not having the thick circular gasket like the Titanic and LMS.
I could cut the outer baffle myself with a router.
Yea that all sounds good, my main argument was with how much material needs to be left beyond the baffle for strength. So ill try to explain as best as possible. The one guy was suggesting a box with the SMALLEST front baffle possible. with that, and a double baffle as you said Erich, the first peice will be recessed, with the other laying atop the recessed piece and the sides where they are all nice and flat.
With that said, say you want the external dimensions to be 20x20 on the front baffle after full assembly. Sounds ok since there is an inch of wood (baffle) on all sides of the driver right? Well, wrong actually! There sure is an inch on the outside layer of the baffle, which the driver is NOT mounted to, on the inside baffle, there is actually now only a 1/4" of material at the centerpoint of each side since the inner baffle would actually be 18.5x18.5 to be recessed into the side panels. Does this make sense now?
While that scenario may not bother some, it has always bothered me. Most dont realize it until it is too late, but when the inner baffle is what the driver is being mounted to, and when you get up into much heavier drivers, I dont want any part of my front baffle, first or second layer at under an inch of wood all the way around the driver on the edges.
EDIT: I just realized my numbers above would be with assumption of total driver diameter, not cutout, but the concept still remains true...