woodworking question

[banjoze]

I want to cut a pattern in a piece of wood to use as a grill/screen for my 2x12. Something along these lines...

http://homepage.mac.com/ryansdesigns/.Pictures/other/DSC04342.jpg


But, the wood I want to cut the pattern is quite a bit larger than will fit in the 16 inch throat of a typical scroll saw. The speakers are closer to one edge of the board than the opposite side, but I'm not sure how I would cut from the other directions. How would you recommend I make the cuts?

[cram]

A plunge router would work too, but you'd have to be pretty skillful with it to manage getting the pattern right or atleast make jigs for the shapes.

If you're really set on that sort of pattern and using your scroll saw - grab a plank of pine (less $) that's the same size. Draw your pattern and Rip it down the middle. then cut out your pattern on each side. then use dowels, biscuts, or some sort of blind joint to glue back together again.
Wipe the joints with water right after gluing to keep that off the peice and in the joint...

just a couple of thoughts.

[Pedro58]

Agreed... skilled router work with a template.

Or cut into two pieces and reglued, sanded, and finished.

[banjoze]

if I use my plunge-router, how do I do the corners?

[Nolatone Ampworks]

if I use my plunge-router, how do I do the corners?

Corners of the cabinet, or of just the baffle board?

As said earlier, a template would be key to this.

Corners of the cabinet, and the edges of the design on the baffle board would be a round over bit for the router.

[DEMENTED]

CNC machine.....

[evacuated]

Drill holes where the corners are and use a jig saw to rough out the holes. Then use drum sanders in a drill to get the final openings perfect. Then round over with a router, if you're going for the look like the one in the pic. Sand, sand, sand, sand until its smooooooth.:AOK