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Discussion Starter · #1 ·
Hi Guys,
Stumbled across this forum when I was looking for some advice on routers seems to be great forum! I was hoping I might be able to get some guidance and advice on some questions I have?

Now I’ll premise my questions by saying that My woodworking skills are very limited (and that’s being kind) so please forgive my questions in advance for the newbieness :)

I’m looking to build a speaker project that uses two bamboo IKEA bowls joined together to make sphere speakers.

I couldn’t include a link as I’m new but they are two bowls 11inches in diameter joined together.

Here’s a pic of one

Wood earthenware Pottery Table Bowl


The speaker driver cutout is meant to go on the bottom base.

Now my main question is what is the best approach using a router to make a recessed hole so that the speaker is flush mounted in one half (bowl) I could use a hole saw but then I wouldn’t be able to have a 4mm recess to make the speaker driver flush.

I’ve bought a jasper jig to make the circular holes but I’m not sure (given it’s not a flat surface) how I would go about doing the cut out.

I haven’t bought a router yet so any suggestions would be appreciated I’ve looked at a couple of routers that are both plunge and fixed but they are getting up there in price and I’m assuming I would also potentially need a router table as well?

If anyone could offer some advice on how best to approach making a circular rebate/recess that would be really appreciated. Baring in mind this will be my first router project and generally new to woodworker.

Also, any comments on a reasonable price setup that would do the job. I don’t want to go too cheap but also would like to keep as cheap as possible given my current skill set! :)

Any advice would be greatly appreciated


Thanks guys



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Hey, Hyped; welcome!
If you fill out your profile the members will know what equipment you have available to you, a first name maybe also?
In any case, if it were me, I think I'd drill out the smaller diameter with a holesaw first, then use that as a template to rout out the slightly larger rebated diameter (the actual recess that the speaker sits flush in).
I'd be a lot more comfortable using a drill press for the smaller diameter hole, with the bowl firmly clamped to the table.
If a guy had a lathe, that'd be another approach.
Having said all that, what you want to do is pretty sophisticated if you've never used a router. For one thing, a handheld router is normally used on a flat surface; you want to do it on a sphere. Not saying it can't be done but I think I'd be using a small trim router to do the rebate.
 

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Theo
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I would say farm it out to someone that knows what they are doing.
 

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When the cost of the equipment to do this is factored in, I'd say that Theo's advice is best, unless you plan on making a whole bunch of these and selling them, In that case you might want to check costs both ways.
 

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Rick
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Guys , wouldn’t a router on a circle jig work perfectly for this?

Btw , welcome to the forum N/a . This is an interesting project ,and looks very cool also . Hope you keep us updated. I often wish I built my home theatre speakers instead of just buying them
 

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Discussion Starter · #6 ·
Hey, Hyped; welcome!
If you fill out your profile the members will know what equipment you have available to you, a first name maybe also?
In any case, if it were me, I think I'd drill out the smaller diameter with a holesaw first, then use that as a template to rout out the slightly larger rebated diameter (the actual recess that the speaker sits flush in).
I'd be a lot more comfortable using a drill press for the smaller diameter hole, with the bowl firmly clamped to the table.
If a guy had a lathe, that'd be another approach.
Having said all that, what you want to do is pretty sophisticated if you've never used a router. For one thing, a handheld router is normally used on a flat surface; you want to do it on a sphere. Not saying it can't be done but I think I'd be using a small trim router to do the rebate.


Thanks mate and noted on the profile I’ll updated.

Yeh maybe I’ve bit off more than I can chew :) if I took the smaller hole out first I was thinking I could build a small box around the bowl where the box is level, flush with the bowl to at least give me a level surface, make sense?


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Discussion Starter · #8 ·
When the cost of the equipment to do this is factored in, I'd say that Theo's advice is best, unless you plan on making a whole bunch of these and selling them, In that case you might want to check costs both ways.


If I can get there with trial and error without killing too many bowls I’m kinda ok with that I guess :) and I’m hoping to do more stuff in future so don’t see investment as a waste if I can reuse the gear.

However as noted above maybe I’ve bitten more than I can chew!


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Discussion Starter · #9 ·
Guys , wouldn’t a router on a circle jig work perfectly for this?

Btw , welcome to the forum N/a . This is an interesting project ,and looks very cool also . Hope you keep us updated. I often wish I built my home theatre speakers instead of just buying them


Thanks rainman appreciated and depending how I go be sure to post and update :)


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Rick
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With a perfect circle jig like mine , the main thing would be making sure you find dead centre .
Once you establish that, the jig I have has a 1/8” pin that requires you to drill a 1/8” hole obviously in the bowl .
From there you do the recess first going around the perimeter with the router on the jig till you achieve your depth , then change the circle jigs distance inwards for a smaller diameter hole that copies the diameter of the speakers inner basket where it seats.
This final hole would go right threw, and presto your done
 

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Discussion Starter · #13 ·
You don’t have to buy one ,as there easy to make , but this is what I’m referring too

https://youtu.be/UkRh68OC_lM


I’ve actually got a jasper jig mate. It’s how to run it on flat surface seeing your working on a dome. Hence my comment about building a box around it flush to give a horizontal surface to anchor from :)




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Excellent idea to build a flat surface for it...box would be perfect...

Then a template for the circle and recess...trim router would be easier...Bosch Colt or Ridgid...

Rough cut with jig saw first...use your box for base for the saw...
 

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Discussion Starter · #15 ·
Excellent idea to build a flat surface for it...box would be perfect...

Then a template for the circle and recess...trim router would be easier...Bosch Colt or Ridgid...


Cheers for feedback Nick. I think I might give that a go mate. I’ve got two extra bowls in case (well in the highly probable event I stuff one up) :)

Even if I hole saw out the first cut and then build a circle template for the recess


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Use thin material for the top of the box so you don't need to over-extend the bit...
 

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Discussion Starter · #17 ·
Use thin material for the top of the box so you don't need to over-extend the bit...


Thanks for advice makes sense! Recess only needs to be like 4mm so assuming if I keep the thickness of template under say 6-7mm should be ok for most decent routers?



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Some additional info...make sure you route in the correct direction...handheld would be left to right or clockwise in your case...maybe you know that already...
 
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