[cupnoodles]

there has be a simple affordable tool somewhere that will cut speaker holes perfectly without having to own a garage (i'm in the city) that would cut say 1/2 to 8 inch holes in mdf by adjusting or setting it to do so?

[Photon46]

I don't know of any such tool that will allow you to cut such a broad range of diameter holes. I have a Vermont American adjustable hole saw that goes up to around 2 1/2" or so size holes and it does an adequate job. I've seen adjustable hole saws that are larger in diameter, but they are miserable cheap pieces of junk. Don't know if you've worked much cutting mdf, but I'd NEVER cut the stuff anywhere but the garage or workshop due to the copious amounts of dust that's generated. It's impossible to contain, floats everywhere through the air, makes a general mess. In short, 1/2" to 8" holes require several tools to do well. Perhaps you could contact a cabinet shop about cutting these holes for you. Likely to cost much less than buying tools to do the job.

[Mr Content]

A "Jasper" hole jig and a router is the only way I know to cut different holes accurately with any sort of ease, but as mentioned this will make dust from breakfast to teatime,........in other words ,lots. You could make your own circle jig, but the Jasper is cheap. You could use a jig saw, lot less dust, but not as accurate, and if you don't want to rebate the drivers into the baffle, flush mount, it will do fine. 

Mr C

[bpape]

http://www.holepro.com/powerseries.html#Twin-det

These are pretty sweet. They're used to be used a lot for cutting holes through home exteriors.  The dual blade will keep things better balanced and you can get a shield for it to keep dust contained anyway.  It only goes down just under 2" so you might need to add a couple of standard hole saws for smaller things like ports.

Bryan

[bprice2]

Check out the Rotozip Spiral Saw.  You will need the attachment that allows you to cut holes.  It works great and is relatively cheap.

[panomaniac]

I had problems with the Rotozip bits bending and pulling. Much like a jig saw blade does.  Have you had that trouble?

[Scott F.]

The Rotozip is a decent tool for small jobs but it isn't built to take teh repeated stress of cutting holes for speakers. Even after moderate use for simple things, my bearing has shot craps.

The best portable tool to suit your needs is a good old fashion router. That and a circle jig. You can do the Jasper (got one) or one of the other after market jigs. All in you'll be $200-$250 and you'll have a tool that should last a lifetime.

[S Clark]

The best portable tool to suit your needs is a good old fashion router. That and a circle jig. You can do the Jasper (got one) or one of the other after market jigs. All in you'll be $200-$250 and you'll have a tool that should last a lifetime.

If you are going to do this, get a router and a circle jig- it's the right tool.  You can get one on Fleabay for $30-60, add a circle jig and a spiral upcut bit and you are set for about $100.  Plunge routers are nice, but a plain one will work. Otherwise, take it to a shop and pay to have them done.

[bprice2]

I had problems with the Rotozip bits bending and pulling. Much like a jig saw blade does.  Have you had that trouble?

I've only cut two 14" holes through 1/4" MDF.  It worked great.  No bending or pulling.

[S Clark]

I've only cut two 14" holes through 1/4" MDF.  It worked great.  No bending or pulling.

I hope you are not using 1/4" MDF for speaker cabinets  .  I think you'll find 3/4" a bit tougher to cut.

[srb]

I hope you are not using 1/4" MDF for speaker cabinets  .  I think you'll find 3/4" a bit tougher to cut.

About 3 times tougher.  If you are using 1/4", you will need to design for BFC (Baffle Flex Compensation). 
 
Steve

[Wind Chaser]

You can make a circle jig for next to nothing.

                                                     Here's a video of one in action.

[bprice2]

I hope you are not using 1/4" MDF for speaker cabinets  .  I think you'll find 3/4" a bit tougher to cut.

My bad...I meant 3/4".  But still, cutting with the Rotozip was not tough, it was very easy. 

[srb]

My bad...I meant 3/4".  But still, cutting with the Rotozip was not tough, it was very easy.

Do you think you might have used a better bit (thicker, carbide, etc.), or do you think other users might have been forcing the tool rather than letting it cut at it's own pace?
 
Panomaniac said he had problems with the Rotozip bits bending and pulling, and Scott F. reported that even after moderate use for simple things the bearing was shot.
 
Just trying to figure out if the tool is worth buying for a variety of tasks.
 
Steve

[nicksgem10s]

I purchased a Ridgid router for speaker building about two years ago.  I would not skimp on router quality since you should have it for many years.  I have also heard great things about the Porter Cable routers.

I really like the Jasper Jig from Parts Express.  Just make sure you get a 1/4" router bit since that is the size the jig measurements are based on.  It allows very precise holes for speaker construction.

I would also recommend getting very high quality router bits.  There is a pretty steep learning curve when you are getting started.  I have learned a ton in the last couple of years and picked up many power tools and accessories.

I still have a great deal to learn.

There are many helpful people here on AC.  I have also learned a bunch about tools for speaker building on the Hawthorne Audio forum.   

-Nick

[panomaniac]

Good to know about the Rotozip.  Maybe I was using a cheap spiral bit.

I love to cut with a plunge router and a 1/4" bit, but it does make sooo much dust.  I think the spiral bit and the jigsaw made less dust.  Something to consider.