The panels are cut on the table saw, passing all same size panels through in one sitting without moving the
fence to ensure perfect consistency. The side panels however are cut larger than required by a few millilmeters
which can then be trimmed down with a router and flush trim bit for a perfect finish.
As always, work starts with the baffle. Instead of using my usual DIY circle jig (read a plank and nail), I had some hole
cutting saws which just so happened to be the right size for the drivers. After drilling the right depth of the outer
diameter on the drill press, the remaining material is removed with the router, and then the smaller hole is cut with another
I follow a precise method which I am now comfortable with when building enclosures. Starting with one front, side and top panel
glued as above.
You can see the champfered driver cutout to give it more space to breath in the 18mm thick baffle. My favourite
fixing method, insert nuts, are used to hold the driver in place. This is more out of habit from working with MDF then
a requirement with light drivers in plywood.
The rear panel goes on next, followed by the top. Usually I would have cut the rear panel cutout before
fixing it, but since I was in two minds at this point it was left till later.
The final side is fixed on. Since the side panel cuts are oversized you don't find yourslelf in the position
where one side is too short - an otherwise common phenomenon in my experience ;)
Finally all the sides are trimmed with a flush trim bit for perfect edges...
...followed by a roundover bit on four sides of the baffle, and the two vertical sides of the rear panel.
The enclosures are sanded down first with 80 grit and then finishing on 180 grit. I didn't feel it needed anymore
in this natural wood - a little texture can be good ;)
Three coats of Danish Oil are applied leaving 6 hours drying time inbetween coats.
The box is lightly stuffed with pillow stuffing material left over from another project leaving some breathing
space directly behind the driver.
And finally, you can see the tall thin spikes that the enclosures will sit on.
Each speaker weights 2.4Kg.