Reddit reviews Jasper 200J Model 200 Circle Cutting Jig for Plunge Router
We found 15 Reddit comments about Jasper 200J Model 200 Circle Cutting Jig for Plunge Router. Here are the top ones, ranked by their Reddit score.
Circle cutting jig is great for making speaker cutoutsCuts 256 different circles from 2-1/4 to 18-3/16-inches in diameterPrecision-drilled pivot holes keep pins in selected holesEasily read scale is calibrated for a 1/4-inch router bitMounts directly to the base of 19 different models of plunge routers
http://www.amazon.com/gp/aw/d/B00009K77A
I would say the bare minimum of power tools are going to be a circular saw, jigsaw and drill. Combine the circular saw with a straight edge (i.e. a very straight piece of wood/metal) used as a guide and you can cut out all of your panels.
Then onto the speaker holes. After laying out where the holes will be, drill a hole big enough to fit the jigsaw blade close to the edge of one of the speaker layout lines. Then use the jigsaw to carefully cut out the rest of the hole. This part will take practice to make the best cut. After that, I believe the holes for the rear connections would be all that's left before prepping for construction.
At this point, you have your panels cut and you need to decide where the crossover will live. I'm assuming you have everything to solder the crossover up so I won't address that. But definitely try to plan the placement so you can still reach it somewhat within the box.
Now for the final requirement: Clamps...Lots of clamps. Particularly [bar clamps] (https://en.wikipedia.org/wiki/F-clamp) since they will have the reach to span the length of the box sides when you glue it up.
Of course, this is bare bones. You could always substitute a table saw for the circular saw and a router+circular jig for the jigsaw and get much better results, but I'm not sure how deep you wanted to get into woodworking.
These will really help if you start to get into the hobby more:
http://www.amazon.com/gp/aw/d/B00009K77A/ref=mp_s_a_1_1?qid=1383050908&sr=8-1&pi=AC_SX110_SY165_QL70
http://www.amazon.com/gp/aw/d/B00009K77D/ref=mp_s_a_1_2?qid=1383050908&sr=8-2&pi=AC_SX110_SY165_QL70
Use a hole saw for terminal cups. It's really difficult to cut a hole that small with a jigsaw and have it precise enough for a terminal cup.
TBH, most of us don't use terminal cups. Drill a hole, push the wire through, put a dab of caulk/silicone on the inside. Straight connection=lower resistance=more power. Plus, easier and cheaper.
As for cutting the subwoofer holes, using a jigsaw is certainly a skill you have to develop. It can be done, but honestly, it requires a lot of practice. Once you develop the skill, you can do some pretty cool stuff.
For instance, except for the straight side cuts, I made this with a jigsaw, including cutting out the logo. Triple layer baffle, you can see how close each hole is (sorry for the bad picture, this was from years ago). They were all cut separately, freehand, from precisely measured and drawn lines.
Unless you want to put the time in practicing, best bet is a router with a circle jig. Find perfect center, drive in a nail, pop on the jig, plunge and spin, perfect hole.
If you have a router, I highly suggest a circle cutting jig. I have this model. I fussed around with hole saws and bought a cheap 6" one for my cornhole set like the other commenter, but when I finally decided to pay $36 for a piece of plastic, I kicked myself for not doing it sooner.
I've had good luck with Porter Cable and Bosch routers. For speaker building I recommend getting some type of plunge router with a jasper circle jig.
http://www.amazon.com/Jasper-200J-Circle-Cutting-Plunge/dp/B00009K77A
I do a lot of car and home audio, and that jig is one of my favorite tools. Perfect circles everytime.
jasper jig
Circle cutting jig
Jasper 200J Model 200 Circle Cutting Jig for Plunge Router https://www.amazon.com/dp/B00009K77A/ref=cm_sw_r_cp_apip_tZhUbQRf5kleA
In all the speakers I've built, I didn't just cut a circle but actually cut a rabbeted circle around the edge for the lip of the driver to sit in. I think it looks much nicer but you could certainly do without it if you don't mind the look.
I cut mine circles with a router and one of these though you could pretty easily build your own jig if you didn't want to buy one. Cut the rabbet first and then cut the through hole after that. With this setup, it'll take you 2 minutes to cut a perfect speaker hole of exact dimensions at exactly the spot on the board you want it. I can't imagine trying to do that without a router - it'd be a freaking nightmare.
As for making your cuts, a jigsaw isn't going to produce very pretty cuts. A circular saw with a straight edge will do the job far better. That setup would effectively give you a tablesaw except upside down.
If you're strapped for cash, doing this one time only, or just trying to figure out if you're into the whole building thing, maybe get one of these. It's not a high quality tool, but it'll cut. I'm sure HF has some routers that would work with the jib above, but make sure the bolt hole patterns are supported. Oh, and never go into HF without a 20% off coupon - they're in every newspaper and magazine all the time.
Edit: Also use the router + a round over bit to round over the sharp corners on the box!
CNC is going to be the most accurate. You can also get a circle jig for a router.
A jasper jig is exactly what you need... Harbor freight probably has them too.
http://www.amazon.com/Jasper-200J-Circle-Cutting-Plunge/dp/B00009K77A/ref=pd_sxp_f_pt
Router Circle Jig
Use a router + a circle cutting jig.
Something like this would work if you're looking for a commercial solution. It's also possible to build your own. Not much too them.
"perfect"
Pretty sure I can do it quicker with this and have the ability to change the diameter by 1/16ths