How to Make Subwoofer Cutouts

By William Kinsey

Having good subwoofer cutouts is very important in speaker enclosure construction. The better the speaker cutouts are, the easier it is to secure the speaker to the enclosure. Good cutouts also make it easier to make an airtight seal between the enclosure and the speaker. Cutting detailed holes can be a challenge without the right equipment. Jigsaws are the most common tool used for cutting subwoofer cutouts. By using some careful measurements and a steady hand, you can make good speaker cutouts every time.

Step 1

Measure the outside diameter of the subwoofer. Subtract 1/2 inch from the speaker diameter. For example, if the speaker is a 10-inch subwoofer, then the diameter is 10 inches and your final measurement is 9 1/2 inches.

Step 2

Set the compass for half the result found in step 1. In this case, the compass should be set at 4 3/4 inches. Draw the circle on the plywood using the compass. Measure the circle again after drawing it to make sure it is the correct size. Drill a pilot hole in the plywood close to the inside edge of the circle that was drawn.

Stick the jigsaw blade through the hole and start the drill. Follow the line of the drawn circle all the way around until the plywood forming the inner circle falls out.