BillFitzmaurice.info

Just out of curiosity... how many db am I losing across all 4 x 24" vs 30"? I can't find the tool used to figure that.

DJ.LJ wrote: ↑Thu Apr 23, 2020 11:34 am I could just keep the T39s I have for that purpose but... I was thinking it would be lighter. You know what?>? I just realized that they won't be any lighter!! Given that they are 9" taller and almost the same footprint.

Now I am second guessing my whole decision on the sizes. I could actually fit 4x30" along the length of the trailer and still have space for the DRs and maybe the amp rack.

Too late now.. I already cut almost all the parts! If it doesn't rain I will cut the last sheet today.

Maybe I should have said something earlier, I guess I didn't quite realise how far along you were.
Having said that, my intention isn't to make you second guess your decisions.

DJ.LJ wrote: ↑Thu Apr 23, 2020 2:20 pm Just out of curiosity... how many db am I losing across all 4 x 24" vs 30"? I can't find the tool used to figure that.

Probably 2 to 3dB per cab. It doesn't sound like much, but it all adds up.
It's not without cost though, more ply, more PL, more pack space...

Thanks Grant. I will keep chugging along with this plan. I’ll update later the progress for today.

Build Session #4 - Time .. about 1.5 hours

OK..it rained most of the day so I didn't get so much done.

I cut the last sheet today. Easy.
Trimmed all panel 1s then drilled out all the dowels from side to panel 1.
Used dowel jig for the panels. That is it for today. Hopefully glue those up tomorrow!

Build Session #4 - Time .. about 3 hours .. Total time so far 10 hours

Ok.. I have not updated the project for a while so I will post the following days all at once. Each day per post.

Got the last of the panel cuts completed.
This day I was doing dowels testing. I did like the ease of assembly it offered but once I got to the inner panels I use the screw poking up through the bottom. I may go back to dowels.. not sure yet. I have the Dowel jig which makes them pretty simple to line up.

Build Session #5 - Time .. about 3 hours .. Total time so far 13 hours

Ok.. this day I routed all the handle holds into panel 1. I goofed on the first one because the clamp slipped on me. I screwed the rest down so it wouldn't happen again. I need to pick up some double sided carpet tape to hold pcs together! I would have saved a bunch of time and not have to fill a bunch of holes later.
Then I marked all the panel lines onto the side and pre drilled some holes for holding the panels in place when assembling.
I was able to PL all the panel 1's easily with the dowels.

Build Session #6 - Time .. about 1.5 hours .. Total time so far 14.5 hours

This day consisted of routing out the baffles. I used a circle cutting jig. I goofed up trying to cut through the entire thickness of the wood and messed up my bit. I had to get another bit and only dug in about 1/8" of material at a time. This was much smoother and had no further issues cutting the baffles or the anchors.
Taped off the centering hole so I could easily find it for the next cut. I used a 1/8" drill bit into the center of the cut to center the jig.
I was looking through the scrap cutoffs for making all the anchors and didn't find any for the 24" to work. I looked on a shelf and found wood from my original builds 9 years ago!! BONUS!!
These are all my pcs for the DR 250s waiting to be put together... it will be done after these!

I always screw router templates in place. You're going to be filling holes any way, so a few more won't make any difference. Filling holes is a lot easier than filling screw ups.

Build Session #7 - Time .. about 3.5 hours .. Total time so far 18 hours

Ok.. cutout the anchor plates, routed the holes and attached some baffles.

I did not bother cutting off the corners on the anchors. I just sanded panel 4 a little bit on the corner to make them fit tight. This is where I had wished I new where my brad nailer was. I actually found it the next day!! I had to use screws on the baffle/anchors because I didn't have enough clamps for all 6.

Build Session #8 - Time .. about 4 hours .. Total time so far 22 hours

Finished up attaching panel baffles and started on the panel 3s

Build Session #9 - Time .. about 4 hours .. Total time so far 26 hours

Today I finished up the panel 3s and panel 4s.
I learned from panel 3 that you should used a scrap pc to make a measure jig to cut the panel to final dimensions. I just looked at the book and cut them to that size and they were all about 1/8" too long. I was re-reading the plans again and noticed it says that the numbers given are estimates and you must measure your own build to accommodate your own specifics. From panel 4 on will be totally accurate using this method.

I just took a scrap pc and cut the angle on it then placed it on the side to mark where to cut the panel to final dimensions. Worked great.
I nailed scraps to the baffle to hold alignment for panel 4. I used a couple screws on the panel 3/4 joint to get a good bond and nailed everything up. I accidentally used 1" nails on the scraps and they shot through a little. I just patched it up with PL and used 3/4" from then on to hold scraps. I also put 2 scraps on the inside of panel 4 line to hold into place.

Looking good so far!

you must have some shop space to work on them all at the same time

jimbo7 wrote: ↑Mon May 11, 2020 3:28 pm you must have some shop space to work on them all at the same time

Yes.. but I wish I would have started them at home. My shop is 20 mins away. It would be nice to work on it whenever I wanted, see the kids, grab a bite, take a break... etc.

Now I have to make a trip out of it.

Build Session #10 - Time .. about 4 hours .. Total time so far 30 hours

Ok.. I was able to cut all panel 5s to length. Assemble 3 of them with braces. Then called it quits for the day.
I decided to use all the cut off scraps to make the braces. I think it took me a lot longer but hey.. they are essentially free now!
I remembered having issues keeping the braces in the right place so I first tried PL/nailing scraps to the panels to hold them in place while curing. Did that for 2 of them.

Then I tried dowels to hold them in place. Much simpler to do and more stable.
Last night I did think of another method that seems even better. Use push pins! I could just stick them into the line where I need the brace and let the PL cure then remove the push pins when done. I think I will try that on the next set of braces.