[vlad335]

OK, doing the baffle to my kit and the measurement for the tweeters outside diameter is 3.93". Equates to 100mm but I don't have mm's represented on my Jasper jig. Searches here and on the net provide nothing.

What size is this in inches per a fraction standpoint? What is everyone using to make the tweeter cutouts?

Thanks

[Captainhemo]

3 15/16" = 3.9375"

Set it at that and do a test  cutout in a piece of scrap.

-jay

[vlad335]

Thank you!

Going to eat dinner then will go down and try it. Weird, I tried searching and was using web based fraction calculators but kept getting 3 and 93/100" as a result. 

Going to put these together tonight and fire them up, bare MDF and all. Can't wait for finishing.

[vlad335]

Yes I am math challenged. Anyway...

The dumb questions keep coming.

Regarding the 3/8" roundover inside the woofer hole. Can I do this all around the opening instead of leaving space for the screws? Would a 1/2" roundover be better on a 3/4" baffle or is it not worth doing. Of course I would leave space for the screws with the 1/2"

[Captainhemo]

Yup, you can run it all the way around  the inside.  There is lots of  "meat"  for the screws.
I'd  think there'd be enough for the 1/2"  roundover  but can't say for sure.  I think pretty much everyone just uses the 3/8"  for the woofer cutouts on 3/4" MDF

-jay

Also, if you need to  convert your jasper  incriments to fractions,  just  divide the   #  by 16 , just the way it's writen,  15/16 = .9375, 14/16=.875 and so on ,  HTH

[kc8apf]

I got tired of doing the conversions and having the cutouts always be a little too big.  Instead, I drew up a Jasper-style jig in CAD that covers 30-250mm in 1mm steps.  The design uses a 1/8" center pin and a 1/4" cutter.  I cut it out of acrylic with a laser cutter but I don't have access to a CNC machine so the holes were all drilled manually on a drill press.  If there is interest, I can probably clean up the design a bit and send it out to have a few made with proper tools.

[vlad335]

Yup, you can run it all the way around  the inside.  There is lots of  "meat"  for the screws.
I'd  think there'd be enough for the 1/2"  roundover  but can't say for sure.  I think pretty much everyone just uses the 3/8"  for the woofer cutouts on 3/4" MDF

-jay

Also, if you need to  convert your jasper  incriments to fractions,  just  divide the   #  by 16 , just the way it's writen,  15/16 = .9375, 14/16=.875 and so on ,  HTH

Thank you very much for the help. Really appreciate you taking the time.

The 3 15/15" setting is a tad big. There is a gap. Oh well, that is the way it is going to be as I don't have any other options.

Gluing up the baffles to the cabs now.

[vlad335]

I got tired of doing the conversions and having the cutouts always be a little too big.  Instead, I drew up a Jasper-style jig in CAD that covers 30-250mm in 1mm steps.  The design uses a 1/8" center pin and a 1/4" cutter.  I cut it out of acrylic with a laser cutter but I don't have access to a CNC machine so the holes were all drilled manually on a drill press.  If there is interest, I can probably clean up the design a bit and send it out to have a few made with proper tools.

I definitely could see a use for it. Especially tonight.

I think I will have MDF cabs done for me for now on. Theres a guy on the PE board that did some baffles for me that were excellent. Totally worth it as MDF dust is a killer. Working in the basement its getting up into the house somehow and my wife is complaining her eyes are burning.

[Captainhemo]

Thank you very much for the help. Really appreciate you taking the time.

The 3 15/15" setting is a tad big. There is a gap. Oh well, that is the way it is going to be as I don't have any other options.

Gluing up the baffles to the cabs now.

The  diameter should be very close.... 3-15/16 is only .0075 larger than  spec , that's only .00375 per side.
I can't rember what thread it is in, but I believe  someone (Mike or Larry ? ) posted a link to an adjustable jig so you can get  your cutouts   exact  by using  a pair of calipers.

kc8apf,   nice idea   

-jay

[slosjo]

This craftsman router guide kit is infinitely adjustable.  I used it for my builds, works well.  You also get a bunch of other uses out if it. 
http://m.sears.com/index-g.html#/productdetails/00925179000P?partnumber=00925179000P&sid=IDx01192011x000001

[mlundy57]

The  diameter should be very close.... 3-15/16 is only .0075 larger than  spec , that's only .00375 per side.
I can't rember what thread it is in, but I believe  someone (Mike or Larry ? ) posted a link to an adjustable jig so you can get  your cutouts   exact  by using  a pair of calipers.

kc8apf,   nice idea   

-jay

The one I use is called a router buddy



http://www.amazon.com/s/?ie=UTF8&keywords=router+buddy+circle+jig&tag=googhydr-20&index=aps&hvadid=27113108643&hvpos=1t1&hvexid=&hvnetw=g&hvrand=11036869791975438857&hvpone=&hvptwo=&hvqmt=e&hvdev=c&ref=pd_sl_5iv92y49f8_e

There  is more than one place to get one.

Mike

[vlad335]

The one I use is called a router buddy

http://www.amazon.com/s/?ie=UTF8&keywords=router+buddy+circle+jig&tag=googhydr-20&index=aps&hvadid=27113108643&hvpos=1t1&hvexid=&hvnetw=g&hvrand=11036869791975438857&hvpone=&hvptwo=&hvqmt=e&hvdev=c&ref=pd_sl_5iv92y49f8_e

There  is more than one place to get one.

Mike

First Amazon review states it doesn't fit a Bosch 1617. The router I own... Bummer.

[Danny Richie]

A 3/8" radius to the back of the woofer is just right in 3/4" material.

[lacro]

Too bad the router Buddy won't work as it has the more adjust-ability than the Jasper.

 This is from my build thread when I built the X-LS Encores. The circle cutting base I made is from a scrap of Masonite. It fits 2 different routers, and cuts circles within a few thousandths of an inch (.002"). Cost nothing  


Re: My X-LS Encore Build
« Reply #6 on: 23 Jul 2012, 07:15 pm »


I should probably show how to use my home made circle jig for those that don't already know. I think it's easy to get perfect sizing using this method as I did. I have never used a Jasper jig, but I can't imagine it has every hole spacing necessary for all speakers which would mean a fudge factor instead of precision. However, if I keep building speakers, and I foresee I will, I will probably have to try the Jasper.

Here is how I set the distance needed: I calculate the radius needed for the hole or counter bore from the plans, and measure from the far side of the router bit to the center of the hole needed. I use a caliper to get the exact measurement. I mark the location with a mechanical pencil (thin lead) and drill a 1/8" hole with a brad point drill. It's amazing (or I am lucky) how perfect a hole you can achieve with this method. Only one hole was a little small so I used a 9/64" bit to open the hole, and used the larger hole by pulling the router tightly against the pivot pin (1/8" drill bit) to the outside of the circle while cutting. Worked great!

[mlundy57]

First Amazon review states it doesn't fit a Bosch 1617. The router I own... Bummer.

Supposedly my Ridgid router wouldn't fit either but it does. Plus, you can drill holes in the base plate to fit any router if none of the existing holes match up.

Mike