Groomlakearea51 Posted October 26, 2008 Author Share Posted October 26, 2008 21 Notice the difference between a Heresy-I and a Heresy-II grill blank. Both are identical in size, but because of how the drivers were mounted, the "holes" are different. Heresy-I on the left, H-II on the right. Quote Link to comment Share on other sites More sharing options...
Groomlakearea51 Posted October 26, 2008 Author Share Posted October 26, 2008 22 I've "registered" the motor board previously shown to the saw. I check to make sure I have not made a mistake before I cut the board. Quote Link to comment Share on other sites More sharing options...
Groomlakearea51 Posted October 26, 2008 Author Share Posted October 26, 2008 23 Cutting the board. I cut the vertical first, then cut the horizontal. Quote Link to comment Share on other sites More sharing options...
Groomlakearea51 Posted October 26, 2008 Author Share Posted October 26, 2008 24 Cut out, and I take the grill board and lay it over the template and rough mark the holes. You can also now use your piece of cutout cardboard to do the same thing. Don't get the marker lines too close to the actual hole edges.... Quote Link to comment Share on other sites More sharing options...
Groomlakearea51 Posted October 26, 2008 Author Share Posted October 26, 2008 25 As an example, here's a Cornwall board template Quote Link to comment Share on other sites More sharing options...
Groomlakearea51 Posted October 26, 2008 Author Share Posted October 26, 2008 26 Here's where you must have a jig saw...... Drill a pilot hole for the jig saw blade in each driver hole. Rough cut inside the marker lines to remove as much wood as possible. If you do not have a router.... then you will just have to be very careful and "jig saw" cut out the holes. Very time consuming, looks crappy, and after you have done it one time you will beg, borrow, or break down and buy a router..... Quote Link to comment Share on other sites More sharing options...
Groomlakearea51 Posted October 26, 2008 Author Share Posted October 26, 2008 27 Example of the jig saw blade holes required for the Corwall tweeter/ midrange area. Interestingly, the "double" cutout is apparently the same pattern used on the Heresy-III grills. Quote Link to comment Share on other sites More sharing options...
Groomlakearea51 Posted October 26, 2008 Author Share Posted October 26, 2008 28 Rough cutting out the holes with the jig saw. I'd take a picture of the saw in operation, but it was not a good idea..... picture saw in one hand and camera in the other.... Quote Link to comment Share on other sites More sharing options...
Groomlakearea51 Posted October 26, 2008 Author Share Posted October 26, 2008 29 Cornwall template ready for router work. Quote Link to comment Share on other sites More sharing options...
Groomlakearea51 Posted October 26, 2008 Author Share Posted October 26, 2008 30 In the case of the Heresy's, I have a bunch of spare motor boards from old projects where the motor boards were in such bad condition (like this one....) that their only use is for templates. Quote Link to comment Share on other sites More sharing options...
Groomlakearea51 Posted October 26, 2008 Author Share Posted October 26, 2008 31 Next thing I want to do is cut the grill board material, as in the 1/8" masonite board. So... back to the table saw for proper sizing.... Quote Link to comment Share on other sites More sharing options...
Groomlakearea51 Posted October 26, 2008 Author Share Posted October 26, 2008 32 Ready to cut. IMPORTANT. Make sure that the edge of the piece of masonite is (a) flush against the "fence" or guide rail, and (, the rough side of the board is down (nice face side "up) Quote Link to comment Share on other sites More sharing options...
Groomlakearea51 Posted October 26, 2008 Author Share Posted October 26, 2008 33 Table saw safety..... Use the safety guard and kickback levers over the blade. I never cut wood without that guard down. Quote Link to comment Share on other sites More sharing options...
Groomlakearea51 Posted October 26, 2008 Author Share Posted October 26, 2008 34 Cut the grill blanks Quote Link to comment Share on other sites More sharing options...
Groomlakearea51 Posted October 26, 2008 Author Share Posted October 26, 2008 35 Check your product..... Quote Link to comment Share on other sites More sharing options...
Groomlakearea51 Posted October 26, 2008 Author Share Posted October 26, 2008 36 I needed 6 blanks (3 pairs.... my son's rebuilds, HT pair one, and pair of mahogany H-I's I traded back to fenderbender for pair of Cornwalls). Quote Link to comment Share on other sites More sharing options...
Groomlakearea51 Posted October 26, 2008 Author Share Posted October 26, 2008 37 For those without a table saw, and measurement challenged, here's the dimensions for the blanks. Quote Link to comment Share on other sites More sharing options...
Groomlakearea51 Posted October 26, 2008 Author Share Posted October 26, 2008 38 Next thing is clamping the blanks to the motor board to rout out the holes. Make sure the edges are aligned. Should be about a 1/16" offset all way around to compensate for the cloth over the edges later. Quote Link to comment Share on other sites More sharing options...
Groomlakearea51 Posted October 26, 2008 Author Share Posted October 26, 2008 39 Clamped and ready for drilling the router bit insertion holes. Quote Link to comment Share on other sites More sharing options...
Groomlakearea51 Posted October 26, 2008 Author Share Posted October 26, 2008 40 I will use a 1/2" drill bit for the holes and a "flush trim" router bit to cut the holes. The router bit has a roller on the end which "rolls" along the driver hole edges in the motor board. The router simply follows the template and cuts out the holes to the exact dimensions of the driver holes. Quote Link to comment Share on other sites More sharing options...
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