Davids for Tom

[publicIdaho]

While we are at it, if you are thinking of having a dedicated router under a router table, this big Porter cable is a real workhorse. It has outlasted every other router we have tried and this one is worked as hard as any we have.

[publicIdaho]

Here is the rabbit cut out on the skinny side.

[publicIdaho]

Now it is time to get those angles right - both pieces were just a little long. So it was many trips back and forth to the edge sander, slowly getting those angles just right. This panel will need to be air tight, so the fit needs to be on the excellent side.

After getting the angle and size right, it was time to put on the PL Premium and throw a few pins in to hold it together. I was very careful to only get it on the joint so that I could leave the pieces in so that they dried at the right angle.

[publicIdaho]

Next was adding the hole for the speaker wire into the top section.

[publicIdaho]

Next was putting on the other side panel.

I hit the top edges with the pad sander - this sander has a fairly stiff pad so it works pretty well to flatten things out. Be careful doing this, it is easy go overboard and sand in a low spot. Low spots are a no-no, but knocking down that high spot is good.

[publicIdaho]

Had to dig out our horrible deep throat clamps. They are cheep Chinese junk and are super stiff. Basically have to hit the ends with a hammer for them to slide up the pipe. Thought I was going to break off the handle when trying to tighten them up. Hit them up with some tri-flow oil and that did help a bunch.

But they reached into where they were needed.

[publicIdaho]

Last thing for the day was the pieces for the grill cover.

Laid out the size based off the front panel.

Marked the angle and rough cut it on the band saw.

Of course, the finished edge was straitened out by sanding to the line on the edge sander.

[publicIdaho]

Rounded the edge over with 1/4" round over bit. We always have this bit mounted in the router table.

Because the piece is only 1/4" thick, it has to be set on edge to round over,

Have to put crossovers together now. I want to put them in before I put the fronts on.

Now where is that soldering iron... No really where is it? Damn, another adventure in finding the lost tool. I have to admit that if a tool is less than $20 and I can't find it, I often just go get another one. I am usually money ahead under $20 in the time I save looking for stuff. Of course, I end up with more tools to loose the other tools in.

[AntonZ]

Now where is that soldering iron... No really where is it? Damn, another adventure in finding the lost tool. I have to admit that if a tool is less than $20 and I can't find it, I often just go get another one. I am usually money ahead under $20 in the time I save looking for stuff. Of course, I end up with more tools to loose the other tools in.

Now stop trying to trick us into believing there actually is a downside to having a shop as big and well equipped as what you are showing us

[Boyd]

Umm, i could be wrong, but are those T nuts on the wrong side of the baffle?

[But it Hertz]

He has the access panel on the horn side because he didn't want to be able to see it from the outside.

[publicIdaho]

Now where is that soldering iron... No really where is it? Damn, another adventure in finding the lost tool. I have to admit that if a tool is less than $20 and I can't find it, I often just go get another one. I am usually money ahead under $20 in the time I save looking for stuff. Of course, I end up with more tools to loose the other tools in.

Now stop trying to trick us into believing there actually is a downside to having a shop as big and well equipped as what you are showing us

If it is a problem, all the tools you are seeing are at our shop, so at home, when you need something it is not there. Except of course when you are at the shop and do something a little different, like plumbing or electrical and those tools are at home.

[publicIdaho]

Not feeling so hot today, so only went to the shop to do one or two things.

First was to take off the clamps on the boxes. I really wish I would have put some pocket screws on the other side of the panels that I had access to on the inside. It turned out OK as it was done, but the pocket screws are so much easier.

Made a few marks showing where I would have put some screws if I had to do it over again.

[publicIdaho]

Darn, they did not show up very well, basically on the opposite side of where they are on panel 7 and 9, and one on panel 2.

Popped out the wrap around insert - looking good.

[publicIdaho]

One thing I did want to do was try the magnets I want to use to hold the grills on the front.

I got some 3/8' diameter neodymium magnets on ebay. The plan was to use a Forstner bit (flat bottom hole) and drill the back side of the front panel almost all the way through and insert the magnets from the back side. this way, the front exterior side of the panel is untouched.

I practiced on a piece of scrap and got the depth stop set just right on the drill press. This is definitely a precise operation, only do this on a drill press with a good depth stop. No hand tools here.