Speaker Holes?

[vast]

Any of you wiser members able to give some tips on cutting circular speaker holes?  I tried a jigsaw on some scrap wood today and let's say that the results were not stellar 

[Woodshop Flunky]

A wood router and a circle jig is your best bet: http://www.amazon.com/Jasper-200J-Circle-Cutting-Plunge/dp/B00009K77A/ref=sr_1_1?ie=UTF8&qid=1303927015&sr=8-1

[jmohr1]

I was thinking of just using a hole saw...

[gnateye]

a jigsaw and drill, then hide the ugly hole with a speaker grill

[Woodshop Flunky]

Also, it depends on what size speaker holes you want to make.  A hole saw is simple for smaller holes, and you can get larger ones: http://www.amazon.com/EazyPower-Hole-Saw-CornHole-Boards/dp/B000YC1XUK  However, the larger the hole saw, the more difficult it is to use by hand.  A drill press works well, but depending on the size of the press, you are limited as to how large a piece can be worked.

You can also consider something like: http://www.amazon.com/Empire-Level-27993-Circle-Diameter/dp/B0015YLLM6/ref=sr_1_5?s=hi&ie=UTF8&qid=1303927927&sr=1-5  But then you're back to the drill press.

a jigsaw and drill, then hide the ugly hole with a speaker grill

If you are going to have speaker grills, then yes, use a drill and jigsaw.

[eds1275]

How big are your speakers? Just grab a cheap appropriately sized hole saw, drill a pilot hole, and drill halfway from both sides. For bonus points route the edge of the hole with a slight round over if you aren't using covers.

[vast]

How big are your speakers? Just grab a cheap appropriately sized hole saw, drill a pilot hole, and drill halfway from both sides. For bonus points route the edge of the hole with a slight round over if you aren't using covers.

I'm popping in 4" speakers.  I'd love to use a circle jig but it cost is prohibitive (especially when I only have a loaner router).

Just ordered a set of hole saws from amazon that has a 4" hole saw, it was only £11.  Hopefully it will do the job!  I shall definitely be rounding over the edges 

[gryhnd]

Easy enough to make a homemade circle jig for occasional use out of some hard board or luan:

[WindDrake]

Hole saw. I've got a 5-1/4" one for car speakers, works great on MDF/Particle Board.

[DNA Dan]

I used a hole saw to make 2 X 4" holes for my fans. See reply 54 in my build thread here: http://forum.arcadecontrols.com/index.php?topic=110471.40

I think it turned out really well. Hole saws are not cheap. I paid ~$20 USD for a 4". If you go up to 4 1/2" it's like ~$30 USD. The cheaper core saws only have threads in them. You then have to buy a drill bit adapter that screws into this. It's more upfront cost, but if you need to buy another core saw later on, it's cheaper in the long run. What's nice about this setup is the drill bit helps keep is lined up in the hole while it cuts. If you go this route:

1) Drill at the highest speed setting you can.
2) Let the saw "do the work", don't push on it too hard.
3) Make sure you hold it perpendicular to the surface being cut. (Brace yourself nice and solid.)

[eds1275]

I'm popping in 4" speakers.  I'd love to use a circle jig but it cost is prohibitive (especially when I only have a loaner router).
Just ordered a set of hole saws from amazon that has a 4" hole saw, it was only £11.  Hopefully it will do the job!  I shall definitely be rounding over the edges 

Don't forget to go halfway through both sides or you'll have some nasty tearout on the exit side.

[jmohr1]

Don't forget to go halfway through both sides or you'll have some nasty tearout on the exit side.

Would you think clamping a piece of scrap to the back and just going partially into that be sufficient?

[vast]

Would you think clamping a piece of scrap to the back and just going partially into that be sufficient?

I clamped scrap when i was doing my ventilation holes, they came out ok.  I'll try the halfway on both sides trick on a dummy run first.

[alfonzotan]

a jigsaw and drill, then hide the ugly hole with a speaker grill

Ding-ding-ding.   

If you're going to use a grill anyway, who cares if a hole you can't see isn't perfect?

[victorylane23]

a jigsaw and drill, then hide the ugly hole with a speaker grill      

Thats what i did and it looks really nice !!

[Vigo]

You can also buy or make a circle jig for a jigsaw if you are without a router and don't want to buy one yet.

[EvilNuff]

You don't need a circle jig, just get a plastic circle template from a craft store you should be able to find one with a 4" hole in it.  Then use a pattern or flushmount bit or a bushing with a straight cut router bit.

[mgb]

How about something like this
http://cgi.ebay.com/Adjustable-Drywall-CIRCLE-HOLE-CUTTER-BIT-SAW-DRILL-/370497949416

This one says drywall but I bought one at Home Depot once that was fine for wood and mdf