I can't believe I did this...

texendo · « **on:** 4 Nov 2006, 02:33 am »

Just received my modded B200s from Planet 10 HiFi today (phase plugs etc.). I've been waiting on them for a while, so I've had the chance to construct a pair of winged baffles. Actually, I've been waiting on them for a long while, because I've also had the time to hand finish them with a few coats of tongue oil. Here's the kicker: I made the frigging circular cutouts about 5mm too small somehow!! What a dumba$$!!

So is there anyway I can make the circular cutouts any bigger? They were originally made with a router and jig, so they look really nice right now, just too small (oops). Is there perhaps a series of router bits I could use to gradually increase the size of the circular cutouts? Any suggestions would be greatly appreciated, and thank you very much in advance.

ebag4 · « **Reply #1 on:** 4 Nov 2006, 02:40 am »

Hi Texendo, I had pretty good luck with a small drum sander on a drill, works well for small changes. If you need a lot of change you stand a greater chance of enlongating the circle the more material you have to remove. Just keep the drill/drum sander moving around th circle to keep it round as possible.

Good luck!

mgalusha · « **Reply #2 on:** 4 Nov 2006, 02:42 am »

If you still have the jig you could attach another board behind the baffles to hold the center pin of your jig and then use the router and jig to cut them again.

nodiak · « **Reply #3 on:** 4 Nov 2006, 03:05 am »

mgalusha's idea plus a piece equal to the baffle thickness glued on, so you're level with the baffle face.

Could even use the cutout you originally made with a board behind it (temporarily) screwed into the baffles from behind - if you feel you can line up the pilot hole where it was when you did the circles.

If you're worried about scratching the baffles with the router plate you can sand the plate smooth with ~ 150 g first (and wipe it down, make sure the screws are sunk in). Or rig up a cardboard or plastic guard with a circle cut out (1/8"+ oversize), could tape it on around the back.

Don

JohninCR · « **Reply #4 on:** 4 Nov 2006, 03:09 am »

I just went thru this. Yes use the original cutout. Screw or nail it to a larger board.
Clamp the baffle to the same board. Find the center point and route again. There
are other ways, but that's the easiest.

Midnite Mick · « **Reply #5 on:** 4 Nov 2006, 03:27 am »

Depending what you are comfortable with but another option could be to cut another piece the exact same size as your baffle. Make a correct size cutout in that piece, and then put it over top of the baffle and use a flush trimming bit.

Would then have to make the recess again for the driver though.

Just another idea.

Good luck,
Mike