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8th March 2021, 08:51 PM #1
Creating inlay templates to an exact size
Hi Folks,
I’m currently building some speaker enclosures and need to work out the best way to route a rebate for the speakers. I’m not sure on the easiest way to do this so thought I would ask for assistance.
The speakers are squarish but with curved edges. I can trace the outline, but it’s not easy to measure accurately. The speakers need to be rebated 5mm so this rules out creating a template of the speaker and then using a pattern bit that I have (which has the bottom bearing).
I have the Carbatec inlay kit which I thought would be handy to use. The problem I see is that I need to be able to accurately trace the speaker, and then offset this by 3.2mm (measurement taken of the offset from the inlay bit and the brass guide) to enable this to be used as the template. I’m guessing I could potentially do this, however there is a fair margin of error and once I have cut the template larger than the speaker, if it’s off I need to start again.
So it boils down to if there is an easy way to make an inlay template sized to match the inlay proposed. All of the research I have found seems to just have a template and then the inlay is just what is produced from the template.
The other option is to shell out and purchase a template following bit - but ideally I would like to use the inlay bit if it’s possible.
Cheers
StinkyNow proudly sponsored by Binford Tools. Be sure to check out the Binford 6100 - available now at any good tool retailer.
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15th March 2021, 08:54 PM #2Taking a break
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Could you make a template of the speaker, then use a pattern bit with a bearing larger than the bit to make a second larger template?
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15th March 2021, 09:25 PM #3GOLD MEMBER
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I've done quite a bit of this type of work. Is the speaker round? Do you have a router circle cutting jig, or can you make one? Do you have a set of router guide bushings? What you need to do is cut a rebate to mount the speaker lip on and a hole inside this to recess the speaker body in to?
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15th March 2021, 09:28 PM #4Taking a break
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15th March 2021, 09:40 PM #5GOLD MEMBER
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Thanks, I missed that, ascribed that info. to the speaker enclosures not the speakers themselves. So can you cut a square template accurately to the size you need? It shouldn't be that difficult to cut the radius on the edges with a pattern or template bit. This type of work is much easier to do with a set of router guide bushings, you can use larger bits so you don't have to worry about the bit only cutting a 1/8" wide recess and you can use the same template to cut both the speaker mounting recess and the hole for the speaker body. Inlay kits are really only for doing inlay work, not offset work like you're trying to do.
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15th March 2021, 10:55 PM #6
Creating inlay templates to an exact size
Thanks for the replies. I did the job on the weekend, this is what I ended up going with:
1. I looked up the speaker manufacturer and found the data sheets in pdf format which provided a line drawing of the speaker;
2. The pdf was loaded into Autocad and converted into a cad file;
3. I used the offset command to offset the outer line of the speaker the same distance of the inlay guide and bit (2.5mm from memory);
4. Printed out the offset line drawing and transferred this onto 6mm mdf;
5. Over sized speaker opening was cut in the template;
6. Template as taken for a test drive using the inlay kit on scrap and tested against the speaker;
7. Any minor adjustments were made and then onto the final product.
Whilst this was not ideal it worked fairly well. There was only one template that was completely scrapped.
I purchased a circle cutting jig which was ideal for this type of work and certainly paid for itself in accuracy, speed and simplicity. After I ran the inlay with the 1/8" bit to create the slightly square profile, I then cut the circle from the middle and used the straight bit from this (1/4" from memory) to clean up the rest of the squarish rebated area. Sounds more complex than it was.
If this was a regular think I think the purchase of a pattern router bit would be worth while.
CheersNow proudly sponsored by Binford Tools. Be sure to check out the Binford 6100 - available now at any good tool retailer.
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