hi all,
i'm installing some new mids in the doors, and need to make up a new panel to mount them on.

what is the best way to cut a perfect round circle for 5.25" and 6" holes in the MDF?
(i've done it for woofer holes as it easy to cut with a jigsaw cause there's more room to play with)

is there a proper tool/drill bit hole cutter etc,
or is it like drilling hundreds of small holes around the circle and then sanding it as close to round as possible?

any help would be much appreciated

well unless you've got a cnc router in your backyard your stuck with the jig saw
or you could buy a trimmer from bunnings with a straight cutter in it and set it up to run in a circle
or just use the jig saw and go slow, then sand so its close to a circle

you can circle jig a normal router to, you just have to put a center pin on an mdf base first, THEN mount it to the router, then drop the pin in a hole on your baffle and proceed to cut hole :)

just jigsaw it, youll be right. if you cant cut around a radius that small, go buy some blades that are made for tight corners (larger teeth and smaller solid section on the blade).

Make a templet hole out of cardboard if your unsure on the hole size. Cut and hack at that until you get it right then use on the mdf and cut with a jigsaw.

You will never get a perfect hole, but as long as you cut it so the speaker is mounted flush and their is no gaps for the air to escape, your away!!

Use the jigsaw to get the hole roughly right, then use a big**** chisel to get it perfect. Worked brilliantly for me... on a 12" sub box. 6" isn't that small though, and less to chisel too.

thanks guys, managed to have a go... not a bad effort
cheers all

Make a templet hole out of cardboard if your unsure on the hole size. Cut and hack at that until you get it right then use on the mdf and cut with a jigsaw.

You will never get a perfect hole, but as long as you cut it so the speaker is mounted flush and their is no gaps for the air to escape, your away!!

or forget the cardboard all together and just use a compass :)