I am out in NY at a project that is still in the construction stage. All wire is pulled but it isn’t time for trim yet. I came out to get the lighting system fired up. When i got here i found all of our porch/deck speaker wires coming out of tiny holes instead of their brackets.
The ceiling for the covered outdoor areas are wood. Plywood then tongue and groove slats. 1-1/4″ depth with tons of nails. About half of the speaker locations had a hole large enough for me to get my hand inside so it was easy to figure out where the joists were. The other half were 1/2″ holes and took 3 times as long because i had to break out my old school tools/techniques to find the center of the stud. Ok i pretty much just used a solid piece of wire and spun it around until it hit something :). It did take 3 times as long because i wanted to be careful and of course the electrician mounted the lights and the fans up against a joist making it impossible to center speakers in some areas.
My first instinct was to break out the sawzall with a thin blade. Since the ceilings were painted and done this idea got thrown out. Second idea was a jigsaw. After counting the number of speakers (20) i decided that manuevering a jigsaw upside down was probably a bad idea. Third idea was to use a Labor Saving Device hole saw. I posted at Remote Central about it. A few people voted for the LSD product. A few for one from another company and one guy brought up the rotozip with a circle cutter. I have some experience with cutting speakers out with a rotozip. It works fine but the bit kept snapping and it was hard to keep the line straight after my arms got tired. The circle cutter might have made it easier. I didn’t think it would be a good fit for wood but it gave me an idea. A router!
I got a piece of furniture grade wood from the cabinet guys. Then i picked up an expensive hole saw and cut a template. I used a countersink bit to drill 4 holes in the template about 1/8″ from the circle cut out so that i could mount it to the ceiling. The speaker bezel/grille covers these holes. The router worked very well. I was able to cut most speakers out with 1 quick pass using a 1-1/4″ bit. The shank on 2 bits broke off when they hit nails. They were $25 each… ouch. Photos below.