The suggestion was brought up-- in the Craftsmen
discussion here-- about using a slot cut out rather than
individual boring with a hole saw.

I think there's merit in this after I've seen how small
variations in vertical line arrays can be visually apparent.

If the goal is to get the drivers as close together as
possible, the slot system has merit.

The mounting surface could be made in a frame of 4
sides and I think that at least dimensioning could be more
accurate (eg. driver widths not matching hole saw cutouts
exactly and thus making the screw mountings problematic.

Only drawback that occurs to me right now is the shape
of the face frame of the driver. This would ideally be as
square as possible.

Are there any further thoughts on this?

The other option is to cut the holes with a hole saw. The holes will be linked so the bracing is still needed. Two baffles can be cut at once if you fasten them to a sacrifical board with nails. I also shoot brads into the inside of the holes so the cut-outs dont move and stay mounted to the scrap board. This way, you can bore the holes, and not have to remove the plugs.If set up on a drill press, this is a fairly fast process. I use compressed air to clean the holes while cutting to lessen the chances of binding.

Hopefully, I will start this project next week!

taylor

taylor