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Cutting 186 Horn Mitres
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Panda View Drop Down
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Joined: 01 November 2010
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    Posted: 09 April 2014 at 9:54am
What is the best way to do the mitres on a folded horn box? I would like to build some 186 Horns, but need to know if there are any "tricks" to getting the mitres perfect. I'm not sure if the calculated angles transferred to a Festool track saw will be accurate enough.? I gather there are also some angle cuts in excess of the capabilities of such a saw?

My initial plan was to have the sides of the boxes CNC cut to give me the folded horn rebates - thats easy, but I would like to do the best job I can of the mitering. Do the flat pack guys also cut the mitre angles on cnc to avoid this issue?
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I've always just adjusted my angle on the saw to whatever angle I need, I'll test the angle cut with a piece of scrap wood and use a protractor or something similar to check the angle and then once the angle is tweaked and spot on I set my fence a little longer than I need and shave it off a little at a time until perfect measurements. 

I can't trust any of the measurements labeled on my wood working equipment, so I use it as a course setting and then finish the fine settings by hand.


Edited by crossed - 09 April 2014 at 10:28am
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Yes a Decent CNC setup will cut perfect mitres, and if you can afford it is the way to go, if you want to do them yourself a rail saw like a Festool TS-55 is the min I would attack with a decent table saw is better and one with a mitre fence (anything over 45 degree requires angling the board onto the blade) is a dream..

One thing I did see on here is a guy axed all his mitres with a router in a jig, I guess you do a rough cut with a saw and them finish with the router, some thing like this :-


he just clamped piece to the sides to guide the panels, very clever..

Smile
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Points: 64 		Post Options Post Options   Thanks (1) Thanks(1)   Quote Fabianm_be Quote  Post ReplyReply Direct Link To This Post Posted: 10 April 2014 at 10:36am
i'm using a Festool rail saw for all my speakers work (mitre or not) and got a good result with a bit of care Smile






Edited by Fabianm_be - 10 April 2014 at 10:38am
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Originally posted by shagnasty shagnasty wrote:

Yes a Decent CNC setup will cut perfect mitres, and if you can afford it is the way to go, if you want to do them yourself a rail saw like a Festool TS-55 is the min I would attack with a decent table saw is better and one with a mitre fence (anything over 45 degree requires angling the board onto the blade) is a dream..

One thing I did see on here is a guy axed all his mitres with a router in a jig, I guess you do a rough cut with a saw and them finish with the router, some thing like this :-


he just clamped piece to the sides to guide the panels, very clever..

Smile



I remember seeing that thread but can't for the life of me find it now. Looks like it could be a good way to do it for those of us who can't afford a decent rail / table saw. Thanks for the diagram, makes it easier to see how it would work.

Does anyone remember the original build thread this idea came from?
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catalin View Drop Down
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Hi there
Try this http://forum.speakerplans.com/pd-1851_topic65709_page3.html
I used the jig whith very good resuts
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Originally posted by catalin catalin wrote:

Hi there
Try this http://forum.speakerplans.com/pd-1851_topic65709_page3.html
I used the jig whith very good resuts


Ah that was it, thanks! Peeping through the slot at the top of the jig I think I can see how you hold the work piece at the right angle. Clever stuff.
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