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Trying to reliably cut big holes


Inetba

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So I finished my first sub enclosure and I realized something. I am horrible at following lines.

I've been reading around and a lot of people recommend a router and something called a "circle jig"?

My question is, I know not every jig works with every router, do you guys have a recommended jig and router combo?

I don't have a lot of time for hobbies, so I'm willing to spend a little more if it means saving an hour.

Also, any corner clamps you guys recommend?

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A jasper circle jig is the most popular choice

http://www.mobilesolutions-usa.com/store/p350/Small_Jasper__Circle_Jig.html

as for the router I believe any plunge router will work with the jig, but someone can correct me if I'm wrong.

also there are large and small jasper circle jigs. The one I linked is the smaller one, if you need the bigger one then it can also be found on that site.

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That's so cool! Thank you. I wonder if any local hardware stores carry that.

Hopefully that will cut down the time I spend cutting out circles in my next box.

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I have this router and the jasper jig and it works great, make sure you get a plunge router to go with the jasper jig

http://www.sears.com/craftsman-10.0-amp-vs-1-3-4-hp-plunge-base/p-00927666000P?prdNo=4&blockNo=4&blockType=G4

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Use 1/2 shank bits less rattle and vibration. Look at a 2.5 to 3 hp one. Around 11 to 15 amp.

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Jasper jigs are worth their weight in gold

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Inetba,

I'm going to present a couple of alternatives to you. I'm not at all saying anyone else's suggestion was wrong, just that there are different ways of getting the job done with the same result.

A plunge router with a Jasper jig is the hot setup, no doubt, but a fixed base router will make the same round hole when attached to some sort of jig or trammel. The two biggest factors in what any person should use would be tool budget, and the number of holes over the least amount of time that person needs to make. If your budget is limited and you only need to make one or two holes at a time, a fixed base router attached to anything that reliably describes the radius of your circle is the most sensible choice. I have made, and seen others make a "circle jig" out of hardboard, aluminum strips, a board, etc., anything longer than the radius of the circle you need to make that you can attach the router base to, for making large radius counter tops and bars. No jasper Jig exists for that purpose and these are items that are created to be viewed, unlike a speaker hole,......the results speak for themselves. I'm telling you this so that you aren't hampered by lack of a fat bank account or lack of available tools.

Next, you don't need a big router or half inch shank bits for cutting speaker holes. A jasper Jig is designed to be used with a 1/4" straight bit. Why would you need a shank, the part held captive in the collet, any bigger than the cutting end? A 6 amp laminate trimmer motor will easily drive a quarter inch bit, just make multiple passes. Watch a few videos and you will see that we're spending more time talking about cutting holes than it actually takes to cut them.

I almost forgot....you can also create a jig for your jigsaw and a very narrow blade to cut perfect circles. Food for thought?

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If they made something like the jasper jig, but for jigsaws, that would be the best solution. However when I was building my box, accidentally making the holes too big is much worse than making them too small and I'm horrible at following lines so it ended up taking me a little over an hour to cut the hole for my one fifteen.

I don't get very many days off work, so anything to speed up the process is what I need. My next box is going to have two 6.25" holes and two 13.875" holes. As for not having a lot of use for it, I plan on making many many speaker boxes and after my friend sees my dual 15 speaker box, he will probably want one for himself. If I can cut down the time it takes to make a box from 7 hours to even three hours (corner clamps would've also helped with that) then I could probably make my money back by making boxes. All the local shops charge $350 for a custom box and I can charge a lot less than that.

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Inetba,

I'm going to present a couple of alternatives to you. I'm not at all saying anyone else's suggestion was wrong, just that there are different ways of getting the job done with the same result.

A plunge router with a Jasper jig is the hot setup, no doubt, but a fixed base router will make the same round hole when attached to some sort of jig or trammel. The two biggest factors in what any person should use would be tool budget, and the number of holes over the least amount of time that person needs to make. If your budget is limited and you only need to make one or two holes at a time, a fixed base router attached to anything that reliably describes the radius of your circle is the most sensible choice. I have made, and seen others make a "circle jig" out of hardboard, aluminum strips, a board, etc., anything longer than the radius of the circle you need to make that you can attach the router base to, for making large radius counter tops and bars. No jasper Jig exists for that purpose and these are items that are created to be viewed, unlike a speaker hole,......the results speak for themselves. I'm telling you this so that you aren't hampered by lack of a fat bank account or lack of available tools.

Next, you don't need a big router or half inch shank bits for cutting speaker holes. A jasper Jig is designed to be used with a 1/4" straight bit. Why would you need a shank, the part held captive in the collet, any bigger than the cutting end? A 6 amp laminate trimmer motor will easily drive a quarter inch bit, just make multiple passes. Watch a few videos and you will see that we're spending more time talking about cutting holes than it actually takes to cut them.

I almost forgot....you can also create a jig for your jigsaw and a very narrow blade to cut perfect circles. Food for thought?

unless he buys a base with the router which will be more expensive for a good one... The jasper and plunge is the way to go.. and there are plunge router tools to cut up to 54" hole i have one somewhere just didnt like it

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