I've been using a jigsaw the whole time and I was wondering if anyone has come up with a better way or what is the best blade for 3/4" MDF... It's kind of a pain following the line with my setup...

 

Alright so I've been reading that a router is a good way to do it.

Another suggestion was to trace a hole around the sub, and line the outside of the jigsaw guard up to that...

 

You can get an arm with a pin in the end to attach to the base of the router. You drill a hole for the pin at the center of your woofer cutout, put the pin in the hole, and use the router like a compass. It makes a very nice round, smooth hole. I believe that the pivot arm is called a "trammel point".

That reminds me: I need to get a router.

 

Yeah that's what I was reading about. But I'm wondering if I should just tough it out with my jigsaw...

 

Router & circle jig are the only way to go.

 

What is a "circle jig". A pivoting arm?

 

Jasper Circle Jig (Model 200) :
http://www.partsexpress.com/pe/showdetl.cf...tnumber=365-250

 

Or, if you are not willing to shell out $40 (if you are only going to use it once), you could just use some string and a nail.....not quite as exact, but as close as you need it to be.

John

 

The only problem with a string & nail is exactness. A decent router can kick pretty good & throw you off with the string. If you don't want to spend for the exactness of a jasper jig, there are several "do it yourself" circle jig designs that can be made for under a couple dollars. I made my last one using 1/8" melamine similar to this pic :


The only issue with making your own is getting the measurements down. Plan on wasting one small piece of wood for testing diameter cuts.

 

I just set a 16 penny nail in the center, measured out the proper distance, plunged router, then just kept the string tight. If I jogged in at all, I would just go back and hit that area again (before finishing cut all the way). Turned out fine for me......I guess there are other ways to do it, though. I just threw something together with what i had on hand.

John