Recessing the Waveguide is Killing Me
So we got all the boards cut, got the missing collet, and are ready to make cutouts, but are stumped on the waveguide.
The woofers are easy. I got a Jasper jig and it's very straight forward. The waveguide is a different story. We (my woodworking friend and I) are stumped on how to make a template to make an interior cut. I'm sure there is something very simple we are missing.
As reminder, I'll have a two layered baffle. The 3/4" baffle will be the cutout and the 1/2" will be the recessed baffle. The cutout baffle doesn't bother me because the cut will be hidden by the waveguide's edge. The recessed needs to be pretty exact or will look bad.
We first just tried to trace around the waveguide but per below image, the edge is rounded so it made for a crappy tracing.
Our next try was to use this approach: http://www.exquisiteaudio.com/baffle.html
. The problem is the you end up with a 1/4" gap between the waveguide and the wood edge.
So, I think I have an answer, but am running into another problem. The potential solution is to use top bearing bits around the waveguide. Use a smaller one first to create an outer template, then use a bit 2x the first to create and inner template that the first/smaller bit will ride against. All that should work, but I can't find all of the top bearing bits. My plan was to use a 1/2" and 1/4". Found the 1/2" bit with a top bearing: click here
. No joy on the 1/4" with a bearing bit. Makes sense since with a 1/4" shank and bit diameter, there is no room for a bearing. Ok, so shifting gears, I think why not make the 1/2" the smaller bit and go for a 1" bit? Already have the 1/2" bearing bit, but having a real hard time finding the 1". Here seems to be one (second to the end): http://www.infinitytools.com/Top-Bearing-Pattern-Router-Bits/products/1056/
What obvious thing am I missing?
I'm very tempted to just go surface mount. It looks like Wayne @ PI doesn't recess his: http://audioroundtable.com/forum/index.php?t=msg&goto=38777&SEOS12 EdgeTemplate Attempt (the interior piece is the exact dimension of the WG"