As heathen like as it sounds, a sharp 60 or 80 tooth blade on a table saw would make those cuts and leave a very clean finish.I don't think they look too bad. It looks like they were cut straight with a saw that's meant to cut aluminum. I don't think the structural integrity would be compromised enough to worry about either, given the way they're mounted to the cabinet. I've seen them cut worse before in auctions.
In case you're wondering, i'd choose 2 opposing bolt holes(between the spokes, keep the holes at the ends of the spokes for mounting) for the centerline of the woofer. Then, i'd determine my desired overall width from truncation to truncation and draw a line on the table of my saw exactly half that distance from the inside of the blade and parallel to it. I'd use that line to locate my woofers, just center the bolt holes used to form a centerline over the line on the table at a point where the bolt hole in the portion you're going to cut off is about centered over the saw shaft. I'd clamp the woofer in place, start the saw, and raise the blade up far enough to complete the cut. Drain, rinse, and repeat as necessary.
.......... and it overcomes that whole fitment thing.If you don't have blown 515's to re-cone then this is a great "cost effective" solution that doesn't involve any cutting and you get the sound quality of 515's which beat out 421's (for many applications) IMHO......
Plus, i'm a bass freak. I'll gladly compromise a bit of the original 515's midrange magic for the solid extension of the 515B's.
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