Rabbets, flush mount and router bits

Discussion in 'Home Theater Projects' started by TimForman, Jul 15, 2003.

  1. TimForman

    TimForman Supporting Actor

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    As I begin to build more and different types of speakers I'm finding myself challenged trying to get the drivers flush mounted with the least amount of difficulty. I was looking at the 3" TB driver and decided that trying to recess that thing was too much trouble so I just front mounted it. How do you folks handle all the different sizes of rabbet cuts?
     
  2. Cameron_Peck

    Cameron_Peck Stunt Coordinator

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    You need a circle cutting jig and a router to be able to flush mount your drivers. You can make a circle cutting jig yourself but if you are going to be cutting many different sized holes it may be worth it to buy one. I purchased the Jasper model 400Here. It will allow your router to cut circles from 1” to 7.5” in 1/16” increments. IMHO, well worth the money. If you choose to make your own, there are plans all over the internet.
     
  3. Rick Guynn

    Rick Guynn Second Unit

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    The answer is to forget the rabbet bits and use a straight bit with a circle jig. Cut the recess for the flush-mount before you cut the hole. Works great!

    RG
     
  4. TimForman

    TimForman Supporting Actor

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    I love simple solutions!
     
  5. Brian Bunge

    Brian Bunge Producer

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    Tim,

    That's the same way I flush mount drivers. Worked well on this design.

    Hell, it won't let me link to the image. Here's a thread with the image in it. I'll just link to this thread. Hopefully the moderators won't mind.

    http://www.audiocircle.com/circles/viewtopic.php?t=3315
     
  6. Hank Frankenberg

    Hank Frankenberg Cinematographer

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    Tim, get the Jasper jig, a 1 1/4" diameter rabbit bit and a 1/4" diameter solid carbide spiral upcut straight bit. The 1 1/4" bit is used to do the recess cut, then the 1/4" bit is used to cut the through-hole. I use that combo for all my driver cutouts, just like Brian.
    http://www.geocities.com/hankbond1/index
     
  7. TimForman

    TimForman Supporting Actor

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    That's a much better solution. I started looking at rabbet bits hoping for an "adjustable" one or something. The thought of buying separate bits for each application seemed (and is) ridiculous. Thanks.
     
  8. Brian Bunge

    Brian Bunge Producer

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    Tim,

    You can getting rabbeting bits with different size bearings. I have one of those as well and it's great when the driver hole and recess end up being just right.
     
  9. Allen Ross

    Allen Ross Supporting Actor

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    yeah i am getting one in my shipment from Rockler.com tomorrow, its does , 1/8", 3/16", 1/4", 5/16", 3/8", 7/16", and 1/2" by changing the berrings
     
  10. Jacques C

    Jacques C Stunt Coordinator

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    I have done mine both ways, though the most flexible way is by doing the recess first with a circle cutting jig and then doing the final circle cut. If you have a rabbet bit that happens to have the right width to it then that works easier.

    My super duper circle jig (hardboard with a wire brad as the pivot) worked great through eight speakers, all flush mounted.

    Take care.
     
  11. DaveKahler

    DaveKahler Stunt Coordinator

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    Hey guys,

    Is it reasonably safe to use a rabbiting bit this big in a handheld router?
     
  12. Brian Bunge

    Brian Bunge Producer

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    Dave,

    That's how I use mine.
     
  13. Allen Ross

    Allen Ross Supporting Actor

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    yeah you only need to be concerned about using bits in your hand held router when they get up into the 1 3/4 diameter and have no bearing.
     
  14. Dennis XYZ

    Dennis XYZ Stunt Coordinator

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    John Janowitz mentioned the CMT Grand Rabbet in the veneer thread. It looks sweet. You get a bit and 17 collars to do cuts from 1/16" to 3/4" in 1/64" increments.

    CMT Grand Rabbet
     
  15. Allen Ross

    Allen Ross Supporting Actor

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    hmmmm little pricey to by a bit thats worth more then me router [​IMG] and i got a porter cable
     
  16. TimForman

    TimForman Supporting Actor

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    You justify it by building lots of boxes then dividing the cost by the number of units. [​IMG]
     
  17. Allen Ross

    Allen Ross Supporting Actor

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    spend more money to save more [​IMG]

    if i ever get really serious about DIY, more into designing my own stuff then i might look into it. but seeing that i am currently working on my first mains i don't think i need a rabbit in 1/64 inc [​IMG]
     
  18. DaveKahler

    DaveKahler Stunt Coordinator

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    I'd probably buy it if my $60 home depot router wasn't 1/4" shank [​IMG]
     
  19. Dennis XYZ

    Dennis XYZ Stunt Coordinator

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    Routers are like razors. They practically give the razor away and then sock it to you on the blades. [​IMG]
     
  20. TimForman

    TimForman Supporting Actor

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    Funny, I didn't get the feeling I was getting something for nothing when I plunked down 200 clams for that P.C. router.
     

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