Setback...my neighbor and I got together last night, and using his router and the new Jasper jig, we did the through holes for LF and HF drivers, plus port and terminal cups - all on the baffle. Tonight we were planning to cut recesses/rebates, using his router table and his brand new Sears 1/2" rabbeting bit. We did a test cut on a piece of scrap, and found that the 1/2" referred to the depth of the bit, and the actual width of the bit's cut was only 3/8" - 1 1/4" diameter bit minus 1/2" bearing diameter divided by two. I did an extraordinary job of managing my rage....I'll be picking up a real 1/2" bit tomorrow, so it's not the end of the world, but I have run into another issue, and need some help and advice. We did the port cutout 2 1/2" according to the plans, and I discovered that the cardboard mailing tube I picked up at Staples does not conform to the design specs. Specifically:
1. The 2 1/2" mailing tube, made and purchased in Canada, is 2 1/2" ID, so the tubing does not fit in a 2 1/2" cutout.
2. The tube's wall thickness is roughly 0.1", not 0.03" as specified in Wayne's plans.
Questions:
1. Can anyone on the north side of the 49th recommend a source for a tube that will suit for this application?
2. If 1 is a no go, question for Wayne - would you be willing to sell me a suitable mailing tube? OD = 2 1/2", wall thickness = 0.03", length = 24". (Did I mention I'm working on six identical cabinets for my HT?)
Thanks for any and all suggestions.
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