Need some help with box construction and tools

**Intercooler** · 12-31-2005, 11:07 PM

I tore off the front tonight to cut a new piece and realized that one edge is angled to fit another angled piece of wood. How can I duplicate the angle on the new piece? I only have a circular and jig-saw! The openings for the subs will have to be via jig-saw but what should I do the straight cuts with so it doesn't tear things up? I am also going to make the 1.5" spacer rings I need tomorrow for the subs to space them out. Other than the ID needing to be 11.125" how wide should I go to the OD for the rings? One last question.... when I screw the pieces of wood together should I drill holes through the outer wood or make a starter hole?

**moreboost** · 12-31-2005, 11:28 PM

On the spacers just make them wide enough so that you can screw the sub to them, any wider of a spacer is kinda useless.As for pre drilling screw holes, yes it only takes a few extra sec. and it helps keep from splitting the wood. Now about the angle part for the other angled part, without pics I really dont know what could be done( not real sure what your'e dealing with )

**joakwin** · 01-01-2006, 12:48 AM

if u only have a small amount of wood tools then use the jig saw that u have, most of them the base can turned to do angle cuts, just make sure ur blade is in good shape tho so that its not bending when ur cutting or else the cut won't be straight, i'll have alittle bit of roundness to it
do u know how much the angle has to be cut to fit right?
if not a angle finder will tell u or one of those half round rulers

if so then u should be able to measure it out and cut it, a jig saw isn't the best tool that i would use to get the angle cut but its better then nothing

a router would work better tho

for my straight cuts i like to use a table saw
i try not to use my jig saw for any thing, they work ok for cutting speaker holes out but a plunger router with a jasper jig works better, gives u the perfect cuts everytime

and only make the speaker rings as big as they have to be

laters

**6.slow** · 01-01-2006, 08:18 AM

Pre-drill! If you need a straight cut, your circular saw should have an adjustable table on it allowing you to put it on a bevel. As far as the straight-ness, Get a new blade and clamp a straight 2x4 parallel with your line. You should be able to run the saw along the 2x4 and cut a laser-straight line. Take your time! Circular saws can be great if you don't half-a$$ it, slow down. This is the first time I've seen a thread that I could actually help with. Hell, I'd love to do the cutting for ya, love the smell of sawdust in the morning!

**Intercooler** · 01-01-2006, 09:04 AM

I do some small jobs with wood around the house but am no guru for sure. I will use the circular saw to do the straight cuts. How much is this router setup? Any links to what the pieces look like? Maybe that could do the angled cut too but don't know. If it is a usefull tool I may buy it to have on hand.

On the spacer rings for the subs.... I guess 12" to the OD will give me 1/2" or better to screw too. Since I will be doubling two of these at 3/4" to give me my 1.5" should I just glue them together first then drill the starter holes through them and into the box face?

**cajundragger** · 01-01-2006, 01:55 PM

go with your ID being what the sub needs to seal good, and your OD being the OD of the sub basket plas like a 1/8 or quarter all the way around. So if your sub calls for a 11.125 hole then thats your ID. And if it is 12 inches OD then your spacers will be 12.25 to 12.5 OD dependsing if you go 1/8 inch all the way around or 1/4. To do the angle, set your circular saw on the orignal piece of wood and loosen the screws on the base so you can angle the saw over until it matches the angle, this is if you don't have an angle finder ofcourse. And I like to use elmers regular white glue for mdf when Im glueing pieces on top of each other, stuff is strong like you wouldn't believe and more controlable than liquid nails. So you glue both the spacers together, then glue them to the box, and the screws that hold your subs in will have to go from the subs, through both spacers, and in the box, I like to use t nuts in the box to catch the screws.

Also, not everything has to be perfect, liquid nails does wonders so if you have small gaps (under 1/8 an inch) you can fill them with liquid nails and smooth it out with your finger.

ANd if you get a metal type blade on the jig saw, it won't allow you to chrew through wood very fast so you can cut a more precise circle if you don't wanna drop the cash on a router and a circle jig....

**Intercooler** · 01-01-2006, 04:44 PM

I just got back from Home Depot. I picked up some of that Gorilla glue to put the pieces together. I think I saw that type of glue being used in an audio shop. I hope to have all the pieces cut out an in place tomorrow but if someone can give me the pieces to the router to do these circle cuts and if it is really worth it I may spring for it tomorrow to get the job done.