Making speaker handles

The first thing you need to do is make a template. The size depends on the size of yourhandles you are about to make. Mark out your template design on your piece of ply remember the coller size on your router as this will make the handles slightly smaller, it is best to mark out your design then make it bigger by a few mm depending on the size of your router coller. making sure the ply you use is well over size to leave room for yourclamps etc. The template shown has a few ideas i came up with for handles.



The next step is to mark up your box where you want the handles to be.

Now your box is marked up place your template on your box and make sure it is square to your placement markings.



Now you need to clamp the template in place and drill a hole in the cut out space. Then use a flat drill piece to make the hole bigger, this will allow your router to fit into it.

Useing your router with coller attached (see last photo), Router around your template.

The last step is to repeat this process for all the other handles on your box.

If you want the pro look you can go over your handles with the router again with a rad cutter this will give it a rounded edge. (Advice from Tony a.s.s)If you're using 18mm ply, a 6mm rad cutter both sides should do.

www.freespeakerplans.com/forum/forum_posts.asp?TID=127

Ill post some pics of this when i finish mine off. All that is now left to do is box in your handles from the inside of your cab making sure the box is air tight.

A quick thank you to tony for his imput. I hope this quick guide helps.

Regards

Ben

Sticky?

Beautiful! I like the handle design.

Just two small additions.

1) In these photos you have assembled the box before cutting the handles, this seems intuitive but cutting the handles before you assemble makes rounding over the insides a lot easier.

2) I always use a smaller cutter for stuff like this, means the template has to be a bit bigger but they go through quicker and easier as less material is removed and there is no need to pre drill.



Alf

Alfie i agree with you, i should of, never mind out comes the sand paper lol.

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A couple of other elementary points here. When retro machining handles or any other smallish cutout in the box, there are 2 methods that I've always used for securing the pattern ---1. pin the pattern on the cab in the correct position, or 2. use double sided tape to secure. I've used tape many times usually on a cab that cant take pin holes for a number of reasons.