Cutting out the first baffle disk was a relatively easy task. Although
the cut is rough looking, the sides of the cut are really quite
smooth, and is the perfect 6.7" baffle diameter size required. The
rough edge you see around the baffle disk is actually the thin plastic
protective covering, which will be removed later. The only issue is
the amount of polycarbonate shrapnel produced during the routing
process.
In this image, I have partially vacuumed the area with
my ShopVac. But, to help reduce the amount debris that flew around, I
used a scrap piece of aluminum tubing around the base of the routing
(as seen to the right side of the router) to contain the stuff. I
flipped it over to the side so that you can see around the bit the
kind of flaky stuff this process creates. The next page will show it
in place as I moved on cutting out the other three baffle disks.
NOTE!!! ---During routing, the
polycarbonate gathers a static charge and tries to cling to
everything. Therefore, vision & hearing protection, along with a breathing mask are a must!!! |
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