Rabbets, flush mount and router bits (1 Viewer)

[TimForman]

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?

 

[Cameron_Peck]

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.

 

[Rick Guynn]

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

 

[TimForman]

I love simple solutions!

 

[Brian Bunge]

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

 

[Hank Frankenberg]

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

 

[TimForman]

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.

 

[Brian Bunge]

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.

 

[Allen Ross]

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

 

[Jacques C]

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.

 

[DaveKahler]

Hey guys,

Is it reasonably safe to use a rabbiting bit this big in a handheld router?

 

[Brian Bunge]

Dave,

That's how I use mine.

 

[Allen Ross]

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.

 

[Dennis XYZ]

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

 

[Allen Ross]

hmmmm little pricey to by a bit thats worth more then me router and i got a porter cable

 

[TimForman]

You justify it by building lots of boxes then dividing the cost by the number of units.

 

[Allen Ross]

spend more money to save more

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

 

[DaveKahler]

I'd probably buy it if my $60 home depot router wasn't 1/4" shank

 

[Dennis XYZ]

Routers are like razors. They practically give the razor away and then sock it to you on the blades.

 

[TimForman]

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