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Rounding Speaker Cabinet Edges with a Router: A Step-by-Step Guide

Are you eager to elevate your speaker game and enhance sound quality through advanced design techniques? One such technique involves rounding the edges of your speaker cabinet to combat diffraction and refine sound dispersion. While this may seem like a daunting task, fear not.


With the right tools and some practice, you'll be well on your way to achieving professional-grade results. In this guide, we'll walk you through the process of rounding speaker cabinet edges using a router, ensuring a smooth transition for sound waves and a significant improvement in audio performance.


The video below show's all the tricks I have learnt to rounding over speaker cabinet edges. At the end of this blog, I have also provided some additional steps as well.


Choosing the Right Router: Trim vs. Plunge

Before you embark on your cabinet edge rounding journey, it's crucial to choose the right router for the job. There are two main types to consider: the trim router and the plunge router.

  • Trim Router: Compact, lightweight, and easy to handle, the trim router is an excellent choice for beginners. Its maneuverability makes it ideal for precise work and intricate details.

  • Plunge Router: If you're dealing with larger round overs (12.5mm in diameter and above), a plunge router is your go-to option. Its robust design and versatility make it better suited for bigger projects.

The Method: Step-by-Step Guide

  1. Practice Makes Perfect: Before diving into your speaker cabinets, it's wise to practice on scrap timber. This step helps you get a feel for the router and builds your confidence. Round over all sides of a scrap piece of wood to familiarize yourself with the router's operation.

  2. Gather Your Tools and Materials: Aside from your chosen router, ensure you have safety gear such as eye protection and earplugs. You'll also need appropriate router bits, preferably a 12.5mm round over bit for this task.

  3. Secure Your Speaker Cabinet: Place your speaker cabinet on a stable work surface. If possible, secure it using clamps or a vise to prevent movement during the routing process.

  4. Set the Depth: Adjust the router's cutting depth based on the desired round-over size. Remember, precision is key, so take your time to get this setting right.

  5. Start Routing: Begin by routing the edges gently. Don't rush – let the router do the work. Gradually move along the edge, ensuring a consistent round-over profile. Take breaks to avoid overheating the router and maintain control over the process.

  6. Finishing Touches: Once you've rounded all edges, inspect your work. If needed, lightly sand the rounded edges to ensure a smooth finish.

  7. Clean Up: Clean up any wood shavings or debris from your workspace and the speaker cabinet. A tidy workspace is a safe workspace.

  8. Admire Your Handiwork: Stand back and marvel at the transformation. You've successfully rounded the edges of your speaker cabinet, contributing to improved sound quality and dispersion.

Embrace the Journey

Rounding the edges of your speaker cabinet might seem like a challenge at first, but with patience and practice, you'll quickly become adept at this skill. Remember, the key lies in practicing on scrap timber before working on your cherished speakers. The rewards are significant – reduced diffraction, enhanced sound quality, and a sense of accomplishment that comes from mastering a valuable technique.

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