How to Route a Nintendo Speaker Grill

[johnrt]

I like to share how I did my Nintendo speaker grill using only a router. You CNC guys can stop reading this and instead follow this link.

The build thread:
Donkey Kong Replica: Scratch build using Gaetan's plans

What I used was a DeWalt router and a 8mm straight router bit. Don't drill pilot holes!

The speaker grill in question is this one:


According to the plan the distance between each slot is 16mm. Adjusting the router manually will almost never be accurate enough, so I found this old kitchen side panel which was exactly 16mm thick:


From this I cut myself 6 spacers. The plan further is to add a spacer after each cut.


Then you have to make a jig. Make sure your speaker panel is well fastened to this jig. I screwed it from the back side. That way the screw holes is not visible from the front. Also screw some wood equally thick as your speaker panel to each side of the panel so the router can go smoothly back and forth over your speaker panel. This picture shows the first two cuts. Note the spacer.


Next cut, new spacer. And here you'll see another vital component for the jig. The little Lexan guide that is screwed to the jig makes it possible to move the router back and forth. It has to be something transparent for you to see the pencil marks. You will have to move this Lexan guide for each cut.


Another vital detail: Add something to prevent the router going more sideways than the width of the slot.


A routing tip: Don't plunge the router bit through the wood. Route back and forth while increasingly pushing the router downwards. Do a test run on some scrap wood.


It is very imortant that you screw a scrap piece of wood on the back side where the speaker grill will be. This srap piece will probably be the bottom of your jig. This is what happens if you don't do that:


The result:




I have also done this on another cab of mine (not that nice that one), please check it out:
http://forum.arcadecontrols.com/index.php/topic,142992.msg1494987.html#msg1494987

[wp34]

You CNC guys can stop reading this and instead follow this link.

 

Well done John!   

[winnydapoo]

For what it's worth, anyone in Aus can grab one of these router bits from bunnings which are perfect for the job (they are 1mm-ish bigger than the 8mm John recommends though so factor that into your measurements) :

http://www.bunnings.com.au/diablo-3-8-x-1-router-panel-pilot-bit_p6370455

[ChanceKJ]

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[jennifer]

   Looks as if you learned some of that the hard way, But nice job.

[taylormadelv]

Brilliant! Looks a nice!