Thread: Creating inlay templates to an exact size

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?

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?

Originally Posted by Sir Stinkalot

The speakers are squarish but with curved edges.

That'd be a no...

Originally Posted by elanjacobs

That'd be a no...

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.

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.

Cheers