Best Tool to enlarge speaker cut outs

Willhound

Looking to install my new stereo and speakers tomorrow. A test fit and measure shows me that my current cut outs are 5 1/4" and my new speakers require 5 1/2". And I plan on shifting them over a bit to allow for contours, so the cut will be larger on one side. Best tool I can think of that I already own is my Dremel. Cutting bit and do it fast, or grinding bit and do it slow and sure (and more dust). Thoughts? Different tool? I do have a curve cut jig saw. Maybe work better?

tk1973

Do it al’s Way if you can. I used a dremel and a jig saw and remember it was a pain in the a$$ for me. Also remember to wear a mask. The dust was nuts. 

zaverin1

Jig saw with fine tooth blade

Robs_232

I've done what Al suggested. It does work very nice and makes the project go way faster and easier. If you don't have the hole saw's, I would bet you can rent a set. Might be $60 to buy.

reneechris14

You can put a spacer behind the speakers.
When using the Dremel make sure you go the right way for the tool (cw is ccw). I just put 6 speakers in my 342 yesterday, when with the polk audio DB651 because they fit the hole. Did have to redrill the screw holes.

Liberty44140

Yep I had the same issue, used a reciprocating saw to cut Fiberglass holes larger and a spacer on the arch so i didn’t have to cut the thick aluminum 

Stodge

Used a Dremel with a spiral bit to enlarge the fiberglass holes in my 280 once.  Worked like a champ.

Willhound

I like Al's idea but I need to "slide" the hole over a bit on two of the cuts or else the new hole will intersect with some of the curves on the combing. Sounds like Dremel or jig saw. Will bring both along with shop vac for dust.

Kaptain_Ken

Hi Willhound. I did exactly what you have to do.  I replaced the 6.5” speakers with 8.8”.  I used the JL supplied template to outline the hole. I then cut one side with a rotozip type tool but because I went through several bits, I cut the other side with a jig saw. The jig saw did a better job.  Hope the pics help.

Willhound

Wow! If I had to go that big I'd likely use the jig saw too. Just finished the holes. Just had to trim a bit and the Dremel worked great. Ran the shop vac right beside it and sucked up most of the dust. I love the smell of resin in the morning !

F1100

jig saw FTW

06Rinker270

Are 2006 270 Rinker speakers 6.5''?

JonnyM

06Rinker270 said:

Are 2006 270 Rinker speakers 6.5''?

Yes they are.

06Rinker270

Thank you sir