Flush mounting speakers in cabinets

[donny]

Hello,

To all the people who choose to flush mount their drivers in the cabinets, I have a quick question. On average, how much larger do you make the shelf? I mean - if the driver's outter diameter is 6 1/8", do you make it 6 1/4" or what? I always see these speakers fitting real tight in the cabinets, and it looks awesome, but am unsure how to get those results.

Thanks!

[duanebrown]

> Hello,

> To all the people who choose to flush mount
> their drivers in the cabinets, I have a
> quick question. On average, how much larger
> do you make the shelf? I mean - if the
> driver's outter diameter is 6 1/8", do
> you make it 6 1/4" or what? I always
> see these speakers fitting real tight in the
> cabinets, and it looks awesome, but am
> unsure how to get those results.

> Thanks!
If the OD 6.5" then make the cut 6.5". A router with a circle jig is the best, if not only way to get this look. If it doesn't quite fit then sandpaper will fine tune the recess slightly.
Then paint the recess black to hide the seam between driver and box.

Good luck,
Duane

[paul_n_oneal]

The best advice I can give is buy the driver first. Sometimes the measurements are off a 1/16th of an inch or so. Once you get the driver O.D. measured, then make the hole 1/16th bigger if you plan to prime and paint it. Paint gets thick fast so you need to adjust for this. Another way is to cut the hole exactly. Cover the lip and side with tape so that when painting it doesn't get in this area. After you're done you can take a black permanent marker and color the inside lip if needed. Hope that helps make things a little clearer. Paul.

[matg]

>if the driver frame you are using is round, it is quite simple. Cut your normal hole to mount the driver. now measure the mounting flange from out side edge to the part of the frame that goes into the hole. Using a rabit bit on a router that matches that dimension (usually in the 1/2-3/4" range, depends on driver) cut the rabit to the depth that matches the thickness of the mounting flange and Ta-Da! flush mounted driver! A circle jig on a router works well too. Again, knowing the dimensions of the driver, cut your first circle at the outermost diameter of the driver and only as deep as the driver flange thickness. Next cut your driver mounting hole the size needed. Each cut will use the same center guide hole. Is this confusing enough?

Hello,

> To all the people who choose to flush mount
> their drivers in the cabinets, I have a
> quick question. On average, how much larger
> do you make the shelf? I mean - if the
> driver's outter diameter is 6 1/8", do
> you make it 6 1/4" or what? I always
> see these speakers fitting real tight in the
> cabinets, and it looks awesome, but am
> unsure how to get those results.

> Thanks!

[waynew]

I have had good success with making a trial fit on a scrap piece first. Sometimes it takes a couple of tries to get it just the way you want it. I have found that Jasper jigs aren't quite as accurate as I would like them to be, not to mention that as bits get older, they change dimensions somewhat, and Routers can have some runout in the bearing assembly. For a very professional look, do a trial run on some scrap first. It takes extra time, but you will always be glad that you did.

[johnastockman]

> Hello,

> To all the people who choose to flush mount
> their drivers in the cabinets, I have a
> quick question. On average, how much larger
> do you make the shelf? I mean - if the
> driver's outter diameter is 6 1/8", do
> you make it 6 1/4" or what? I always
> see these speakers fitting real tight in the
> cabinets, and it looks awesome, but am
> unsure how to get those results.

> Thanks!

Wayne is right...I always do a test cut on some scrap to make sure the driver fits exactly...and also wait until you actually have the driver so you can measure it. The published dimensions can be off by 1/16" to 1/8", like Paul said. I use a pair of calipers to take the flange diameter measurement. I haven't messed up a baffle since I started doing it this way.

John A.