XF210 x2!

[rmediacraft]

After my success with the 2 OT12s and 4 T39s, I decided to build a pair of XF210s for Christmas gifts.

We have two boys that play guitar and neither has a proper speaker setup. One is a Pod kid and the other is all about separate pedals. This seemed like the perfect gift for both! However, I have to build during school hours to maintain stealth. It's been in the 60's this week, so yesterday, I snagged a 4x8 sheet of 1/2" ply and today, the sawdust flew.

Got all the rough pieces cut today and will start trimming and smearing PL all over myself. About 4 hours of work today, including various breaks and cleanup. Can't leave sawdust around to raise suspicions...

The cabs will house Kustom/Eminence drivers I found on closeout at PE for $35 each. Nice. They can change them out later if they aren't "cool enough". Wiring them stereo (because I can), but using shorting jacks so they can be mono too. Duratex finish, nickle hardware and some Fender-ish grille cloth. Should be pretty sweet. Looking forward to hearing them.

BTW, after my previous builds, Cutlist is my new favorite piece of software. I could never dream of arranging the bits this efficiently. Aside from the big piece, only a handful of leftovers. Didn't even make a dent in the trashcan!

Here's a few pix...

[erriod]

How did you get cutlist to provide the printup of the 4x8? Everytime I do it, a 6x96" board is selected even though I have selected 'sheets' as well as a 4x8 or even a 5x5.

Stephen

[Grant Bunter]

How did you get cutlist to provide the printup of the 4x8? Everytime I do it, a 6x96" board is selected even though I have selected 'sheets' as well as a 4x8 or even a 5x5.

Stephen

easy, edit it.
Not in 4 x 8, input 48 x 96 instead (4 x 8 in inches).

[rmediacraft]

A little progress today, but only spent a couple of hours actually building. Had to make a new angle-cut sled since I pretty much destroyed the old one a while back. $20 and I'm back in business.

Got one cabinet framed up today and it's clean and square. Forgot how truly messy PL is - especially when you haven't used it in a while. Didn't kill any clothes/shoes/phones, so it's all good.

Just one pic today. Can't work on these again till Monday, so I guess I'll have to change the brakes on the van and repair the attic ladder while the kids are home...

Happy weekend!

[Fenderfan]

I think this is one of the first - if not the first build thread on xf's Ive come across with pics too. I've been thinking about building one for the guitarist in my band (he can put his own drivers in though - I'm not that generous!), but always like to see what I'm getting myself in for before launching into something, so good to see these. Be good to hear your own review when done, and of course the review from your boys when they crack into them!

[rmediacraft]

Sorry I've been a ghost. Way too cold to work in the garage for a couple of days, then photo shoots, kids, life, etc. Finally got a chance to build again yesterday.

Got both cabinets framed up, cleats in one and baffles cut for one. The baffles are a bear. Trapezoids with compound angles - and it's very much a trim-to-fit-the-cabinet thing. It's probably just me, but the plans show how to mark the baffles and include "blade tilt" markings. Didn't work for me. I just have to hold them up and imagine them in the 3D space before they hit the table saw. Yeah, I made some scrap...

Fortunately, I have enough bits and pieces laying around to make new, so it's all good.

The basic framing is easy to put together and makes a sturdy, square box quickly. Perfect for the other pieces.

Note: the last time I built, it was in the heat of summer and the PL cured pretty quickly - at least strong enough for me to keep moving forward. The 50-60 degree temps now make for some seriously slow curing.

Also cut some jack plates out of aluminum bar I already had. Figured it was thin and strong, so a good choice. It was, but next time, I must use a drill press to make the holes. Ultimately, they'll line up fine, but it's a good thing nobody will see the backside. They'll look a little wonky in there

A few more pix for your enjoyment...

[Tom Smit]

Plates look fine! If need be, use a file to clean up around the hole.

[rmediacraft]

I think the holes are fine. It's the alignment that bothers me. Not exactly square on the piece. It's a flattering picture and you can't see the other one

Another quick note for potential first-timers: Huge kudos to Bill for his table saw sled design. For my first build, I bought a simple saw for $75 on Craigslist (probably $300-400 new). The guy had used it for one project and it was collecting dust in his garage. Got it home, cleaned it, downloaded the manual and figured out how to adjust it square and straight. The fence was fine, but after a few scrap passes with the miter gauge, I was a little concerned. Once I had my plans, I built 2 sleds - one straight and one for angles. Wow. Even with my $25 Harbor Freight 60t blade, it cuts laser straight every time. The only variable is the operator. Plus, I feel safer too. This saw has some serious kick-back in its natural state. The sled serves as protection too. Best $1.95 I ever spent!

Also built his circular saw sled - 4 feet wide for big cuts. Really nice, simple solution. Repeatable results every time. Now, if I just had a big, fat table surrounding my saw, I could rip whole 4x8 sheets. Probably not in my garage. My wife really likes it when we can park the van in there

[Tom Smit]

Now, if I just had a big, fat table surrounding my saw, I could rip whole 4x8 sheets. Probably not in my garage. My wife really likes it when we can park the van in there

One of these perhaps?

[rmediacraft]

Oh, Tom. If only... Although, I think I could squeeze one in the garage. Hmmm...

Today was an exciting build day, for several reasons. I finally deciphered the mystery of the 3D trapezoid baffles and managed to cut and fit all four. It took me about 45 mins in Sketchup to really wrap my head around it (and take all the necessary measurements), but I got it, they're done and I'd really rather not talk about it much more than that.

Next, it was time to route out the holes for the speakers. So I secured my trusty old BD router in my DIY circle cutter and proceeded to cut the first circle. About 2/3 of the way through the second pass, I saw some pretty big sparks inside the beast. By the 3/4 point, flames shot out and the speed went way up. Reached for the switch, but it was seized, so I scrambled for the power cord. My faithful $5 rummage sale router was done. Kaput. It made it through several projects, including my 6-cabinet build over the summer, so can't complain.

Now I was stuck and needed a new router. Not being a retail kind of guy, I hit Craigslist first. Found a couple, but they'd already been sold. Next it was the Pawn shops. One store had - I kid you not - over a dozen Craftsman routers, all nearly the same model. They wanted $49.99 for every last one, regardless of condition and wouldn't budge. Seriously? Fine. So I ultimately ended up at Harbor Freight and bought their middle-of-the-road plunge model. I actually like it. Of course, it didn't fit any of my jigs, so modifications were next on the list.

At the end of the day, I felt fortunate to get the cabinets to the final glue-up stage. Tomorrow, I'll install the jack panels, PL the baffles and assemble the grille frames.

Sorry, only phone pix today... and I was losing daylight fast.

More soon.

[rmediacraft]

Big day yesterday - got the baffles secured. Really counting on the PL to do its thing and expand to fill a few places, but based on my inspection this morning, all is well.

Also hit the edges with my rounderover bit and sanded everywhere I could see. Also started filling holes and boo-boos on my part. The pix below look worse than it is. Just little stuff to clean up. Also, the pic of the clamped baffles looks like a serious overlap, but it's just PL squeezout. Looks good this morning.

Finally, put the first grille frame together last night. Shot some brads through for security, but it's really just PL and clamps. Starting to see the end of the journey.

WAY too cold to build today - I think the wind chill is 17F. Brrr. Taking the kids Christmas shopping for mom instead. I'll get the cabs cleaned and ready for Duratex tomorrow.

More phone pix. Enjoy.

[jswingchun]

Also built his circular saw sled - 4 feet wide for big cuts. Really nice, simple solution. Repeatable results every time. Now, if I just had a big, fat table surrounding my saw, I could rip whole 4x8 sheets. Probably not in my garage. My wife really likes it when we can park the van in there

I don't know if you meant ripping 4x8 on your tablesaw or with your circular saw, but if you meant your circ saw with your sled, check this out. It's pretty cheap, works great and takes up little space.

http://www.eurekazone.com/product-catal ... ing-tables

You could buy just the kit, add your own lumber. That's what I did.

[rmediacraft]

Actually meant the table saw, but that's kinda interesting. Bill has plans for a simple floor-based setup. I did the 8' rips on this project by starting with my 4' sled, then finishing by hand. A little more sanding, but still straight overall.

Today, I sanded and filled holes. Surfaces are like butter. Then I installed the grill blocks, so there are a few new holes to fill and sand. Bleh. Also put grille #2 together.

After sanding, the places where the PL fixed my gaps was a little gnarly, so I covered with some acrylic caulk, smoothed with my finger. Says it's paintable - it'd better be!

Broke out my nickel corners today to see how they fit and was reminded of a lesson I "learned" on the last project - a 1/4" roundover bit isn't broad enough to make the corners fit snugly. Doh! Anyone have any wisdom on this? I can easily re-route/sand, but should I look for a 3/8" or 1/2" roundover bit? Used plastic corners last time and, lopped off the corners with a jigsaw and didn't worry too much about the mis-match on the edges. Just cranked the screws in and called it good. Don't think I can use that tact with the metal corners.

Just a couple of phone pix tonight. If you look closely, you'll see a couple of brads that didn't go all the way in. My antique compressor was just too cold to top off the tank for the last nailing. I can fix them tomorrow after the PL sets.

Tomorrow is back doors, final filling/sanding and a primer coat of black. Sunday is Duratex day and the forecast says somewhere between 50-60F. Should be good.

[LelandCrooks]

3/8, set just a tad shallow.

[rmediacraft]

Taking Leland's advice, I wandered off to HF this morning and found a 4-bit set on sale for less than $20. Not bad. Not awesome, but totally adequate for what I'll do with them. Rounded the edges again, sanded again, filled holes again...

It's at this point in the project I have to tell myself to stop. I could sand and fill all day and only make it 1% better. Not. Worth. It.

So I stopped, blew off all the dust and hit both cabinets with a coat of black spray paint. Dang, that looked nasty.

Next was a shopping break - both for Christmas and supper. Check and Check.

After supper, I broke out the Duratex - kindly supplied by Mr. Crooks. God, I love this stuff! If you've never partaken, don't assume it will hide everything 'cause it doesn't. But it does make a hard, dimpled surface that distracts the eye away from any of the more obvious flaws. And it just looks cool. Anyway, got the top, bottom, back and sides covered with a first coat. Left it to dry till morning when I'll do the baffles, etc. Tomorrow afternoon will see the finish pass.

No pix tonight. Broke out the 'real' camera and, for some reason, my card reader isn't working. Just imagine black cabinets.