Another busy Sunday. Kinda pissed at some of the results though
Yesterday I bound two 3/4"x24"x22.5" MDF pieces together to create the double baffle for the IXL18.4.
I crafted up a DIY circle jig using 1/4" MDF, drilling holes for the router base and measured out exactly 8 5.5/16ths which will create the hole for the subwoofer (16 11/16ths).
I used some scrap MDF and tested my circle jig and did a dry fit on my IXL. It Fit perfect.
So at this point I thought I was home free. Should be easy, right?
I then took my double ply 1.5" baffle and drilled a hole all the way through both pieces of bound MDF exactly in the center. I screwed in my DIY baffle using a 1" drywall screw just as I did previously in my first circle test. I proceeded to create a nice circle on on the first side going half way through the baffle using a 1/4" x 1" straight router bit. The circle looked perfect.
I then flipped over the double baffle and did the same thing, screwing into the existing pilot hole I created earlier and again went around creating a circle from the other side.
What I ended up with was 2 mis-aligned circles. The circles are Aligned perfectly on the north and south side but off about 1/4" west and east if that helps explain it better.
I can't for the life of me figure out why or how this happened. Am I missing something here? The only thing I can think of is perhaps the pilot hole I drilled was a little crooked? I remember when I was drilling it, ensuring it was as straight as my eyeball could see.
How is everyone creating thick baffles here?
Any help/insight would be greatly appreciated.
Here are some pics that help explain it better:
My circle jig