Enlarging Speaker Cut Out

[rf7]

I bought a replacement 12" speaker for a Behringer bass combo, and the cut out in the baffle is too small. What is the best way to enlarge that cut out? Has anyone done this before? It's got T-nuts in place already.

Thanks in advance!

[Chuck H]

If the baffle can be removed you can use a jig saw. I don't think you'll be able to do that with the baffle in place because the cabinet rails may get in the way. In that case I suppose you'll need to grind away with any tool that will fit. Maybe a barrel sander on a hand drill with 60 grit paper.

[rf7]

Thanks Chuck for the info. Yeah, I was afraid that I'd gave to do something like that.

[J M Fahey]

Even with cabinet rails, *sometimes* it can be done (I have), by adding some wood pieces as to separate the jigsaw base from the speaker board, yet staying parallel and reasonably firm.
Some saw blades are longer than others and even if it barely reaches "the other side" , it does cut, although somewhat slower.
That extra thickness/height added may let you clear offending borders or rails.
Even if you can't cut 100% of the circumference, handsawing the remaining 10% is much better than 100%.
*Be VERY careful*, it's easier for the jigsaw to slip or whatever and happily chop meat and bone away, and I'm not talking about those ribs you intend to BBQ.