[== 6/30/2009 ==]

So finally Panel 3 is installed.. This by far has been the panel from hell. All is well now though. I test fit the driver with the socket caps. Fits perfectly and no obstruction from any hurricane nuts.

Also a quick tip I thought I'd share. For slow asses like myself that only use a bit of PL every other day, the way I preserve it is by using a spare Nitrile glove an elastic band. Not sure how everyone else does it but this method seems to work for me.

I stick a medium length wood screw in the nozzle.

16 penny nail for me

I like the screw because the the PL hardens on the threads and pulls out like a custom fit plug. It leaves a clean nozzle ready to use. Never used a nail before, might act the same way though.

I might try that way next time if I can remember.
What size screw do you use? 3" wood screw?
How big do you clip your tube tip?

I use a cheap phillips screwdriver, periodically removing dried PL with pliers.

3 1/2" decking screw. Clip the tube just big enough for the screw to fit snugly through the hole.

[== 7/1/2009 ==]

I did some test fitting today on Panel 4 today. It appears some of my Araucoply panels are warped. I am not sure if it was because I was storing it vertical or what. In any case the result of the test fitting is below. I have since stored them in a horizontal orientation.

Looks like I'll be making use of some guideboards screwed to the face to see if I can straighten it out enough where I can secure it to the adjacent panels.

Any other tips on getting these unwarped??

myn, what are you using to hold the panels together while the PL cures?

An eighth inch of warping won't bother fifteen to seventy five foot wavelengths all that much.
If they bother you use a guideboard to pull them out until you fasten the joint.

Had the same thing happen with my BB ply. Just clamp a straight board to the panel as the PL cures, or before you nail/screw it in place...

Looking good. Looks like you are taking your time and doing it right...don't rush. My THT and SLAs took over 7 months to finish....

JSS

1) Line up the next panel using guideboards screwed into the side panel/vertical panels and a roofers triangle to ensure its square
2) clamp
3) predrill screw holes (I go about 3/8" into the piece I'm attaching)
4) unclamp
5) apply PL
6) Clamp
7) screw, making sure to hit the hole on the panel being attached
8) remove/unscrew guide boards (only because I want to reuse them and I want to wipe the PL off of them)

Am I doing something wrong?

What about that little edge? If it's not flush will this cause an issue?

I'm used to traditional alignments where the port path has to be really really smooth or port chuffing is heard.

That edge will cause no issue with the wavelengths concerned, as Bill mentioned. You are good. Your technique is sound as well. Only concern is any air leaks, but you have already said you caulk the joints, so you are good there as well...

JSS

One thing I did do tonight was used a chisel in the interior where the driver sits and scraped off the overflow of PL as the flanges will need to sit flush against the surface. On the opposing side of the panels I caulked it along the edge. As much as I'd like to retain the overflow everywhere I think this is one case where overflow is a hindrance. I am suspecting you did the same thing?