Indignia baffle milling pictorial

RayW

RayW

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Here's how I've been doing Indignia baffles. This is not the only way. It's probably not the best way. However, it is the way I've been doing them.

First, I start with a fixture for holding the baffle while I do my dirty work. (1st pic).

I made up a drill template with the centers for the woofer, tweeter, and port holes. For mirror image parts you just flip it. (2nd pic)

Using the template, drill the center holes in the baffle. (3rd pic)

In order to keep from scratching the pre-finished baffles I use a piece of foam board mounted on top of them. Same as the template, it can be flipped for left and right baffles. I run a drywall screw through the corner, through the baffle mounting hole, and into the fixture to hold it there. (4th pic)
 

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Next step is to get the router and circle jig set up. The thickness of the foam board is taken into account for the depth of the cuts. Go around once (1st pic) and then adjust the radius in and do it again until you get the recess cut out (2nd pic).

Then do the same for the tweeter (3rd pic).

Since these baffles are 1" thick and I have the foam board on top I couldn't get all the way through from the front. I turned them over (mounted on foam) and finished the through holes from the back. (4th pic)

Last pic is the mirrored baffles.
 

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Next step is to make the cutouts for tweeter terminals. I just used a Dremel tool with a drum sander and hogged them out. (1st pic) You can use a jig saw, router, Swiss Army knife, or whatever you want. Just be careful of the finish.

The tweeter recess for the Indignia is a x/32" radius and my jig only does 1/16's so I had to cut small and enlarge the hole. I used the Dremel/drum sander and just did laps around the OD until the tweeter fit. With a Router Buddy type jig you should be able to adjust to the correct radius and skip this step.

Next, I used a Forstner bit to drill the recess for the port from the back of the baffle. (2nd pic)

Then I used a regular cheapo drill bit to drill a hole in the middle big enough for a flush trim router bit to fit through. (3rd pic)

I use a PVC guide for the router/trim bit and clamp the guide piece in my Workmate. (4th pic shows the guide)

The last pic is the port cutouts completed.
 

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Here's what they look like after a pass with a cleaning wipe.

And Ray in full battle gear ready to deal with some MDF. :D
 

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AK's Indignia Baffle SuperHero EXPOSED! :thmbsp:

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Ray, can you make a Adirondak version of the Indignia? You would have to price it accordingly but it would be more comfortable.
 
We KNOW Ray saved all them circle cutouts to build something nifty.

I hear the Indignia Shoebox Railway haulin' a twelvepack for each of us across the yard right now:

"Woo WHOO...!" :banana:
 
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Zilch said:
We KNOW Ray saved all them circle cutouts to build something nifty.
Click to expand...

Look in the top right corner of the drill template picture and you'll see a pile. :D If I get out in the shop tomorrow (it being church and hockey day it might not happen) I'll stack 'em up and add a pic. I'm probably approaching enough to make some stands.
 
RayW said:
If I get out in the shop tomorrow (it being church and hockey day it might not happen) I'll stack 'em up and add a pic.
Click to expand...

Been cuttin' wood all day and finally decided to take a break and gather up the cutouts for a group photo. Standard 16x24 framing square added for scale.

They look a little hairy but they've been living on the floor with the spider webs and sawdust.

I could tell you what the project just to the left on the table is but I'd have to kill you.

Ray
 

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Impressive, Ray. That's similar to my stack, except that 5 of them include thinner material from the inwallnias.
 
I think it's kind of funny that none of those are from my speakers. I did mine fully DIY and I don't think I saved the cutouts.
 
Very nice, Ray! I'm looking forward to receiving your handiwork. It will make the project MUCH more enjoyable for me.

Roy
 
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