Since I used a pre-built and pre-finished cabinet, I thought that this would be an excellent time to talk about some of the tricks for flushmounting non-round drivers. First, let's look at how to flush-mount the Morel MDT-39 (which would be the same recess as for the MDT-12, MDT-22, MDT-40, or MDT-44). This tweeter measures 2-1/8" square, and has approximately a 1/4" radius on the corners. So, we can cut the flush-mount with a 1/2" diameter straight cutting bit, and utilize a collet and wooden template. Wanting to use the smallest collet possible, a 5/8" OD size provides just the clearance for the bit that to make, plus makes it easy to figure out what size template we need. Since the collet adds 1/16" on either side of the bit, we simply need to add 1/8" to the 2-1/8" flange size; hence the template should be a 2-1/4" square. (See the PE website for my tips on how to quickly and accurately make the template). Once we have the template, it is simply a matter of setting the correct bit depth, securing the template in place on the surface of the baffle, and then tracing inside the template with your router. A perfect square-with rounded- corners every time!

The woofer flush-mount was done with the Jasper Circle Jig Model 200. To get ready to make the cut, we need to drill a 1/8" diameter hole at the center of the woofer location. Adjust the plunge router stop to the proper depth, which in this case is 1/4". Insert the Jasper center pivot pin at the desired diameter, 6-5/16" for this particular woofer, and then place the pivot pin down into the woofer center hole on the baffle. Make a couple passes with the router to create the recess for the flange, and then make the cut through the baffle for the woofer. This can be done with the Jasper Jig itself, or can be done freehand with a sabre saw.

Click Here for more information on working with PE finished blank baffles!