Four WH10's without... MY SHOP!

[Curtybob]

Great weather for a few days... thankfully. Because I no longer have a shop. Been a little busy, got the shells all assembled.
forgot to snap a lot of pics, but I did remember to get one of the new cordless nailer which has won me over.

I used it to tack the template for the horn tops and bottoms onto the blanks (precut to size and edge bevels) so I could use a pattern bit and router. note: the pile of rubbish directly under the last piece about to be cut. That is the scraps from the seven pieces cut prior to the pic. Made quick work of the eight pieces necessary. I was going to clamp everything, but the nailer is just soooo damned handy. Plus, the holes are easily filled. The brad nailer has run 6 sleeves of 1.5" 18ga. brads and still shows 3 out of 4 lights on the battery gauge. It is fairly fast (~1 brad/second) and seems more accurate on depth than my old bostitch air gun. No jams yet... but only 6 sleeves in, still lots to go before I say it's reliable and jam free.

Didn't take pics yet, but these are going to be in the flavor of Nimrod's with the radiused front. Having to adapt the plans just a bit, but only a tiny bit here and there.

[Curtybob]

Working outside is taking a huge toll on my organizational process. It's nice to work in the sun, but I miss having some workbench area, some shelves, and some options when it comes to setting up for a cut.

Today, I used the template/pattern bit method to bang out the baffles, spacers, and phase plug extension Except for the mess, it went pretty good.

Baffle template ready to cut.

Getting rid of some wood to make it easy on my router bit.

Tacked down and ready for the router.

Parts cut, ready to go, and arranged... uhhh... very precisely. I need a shop. ugh.

I tossed together a cab to make sure all the radius cuts would work. The horn is tacked into place with a few nails, but will slide back into the shells about 1/4". The resulting lip is where the grill/foam will attach.

[Scott Brochu]

Looking good so far.

Love the rounded fronts. Little bit harder figuring out but well worth it in end results.

[Curtybob]

Nothin' to it. Just gotta add a few bits of ply to the sides of the horn, and don't go overboard with the radius. I used a 60" radius, winds up taking about 5/8" off at the very outside perimeter. I could probably fill the gaps left between the horn and the sheath with adhesive. Nimrod did all the homework in his thread (older version of the plans, obviously), so I just had to figure the minor details for myself. Just finished the rest of the horn assemblies, and if it doesn't rain, I might be able to get all 4 roughed in and get the fronts trimmed up.

[Curtybob]

Last day of big woodwork ahead. Because I decided to take advantage of the weather and build the boxes without the drivers on hand, I can't attach the horns to the shells yet. But, I can absolutely get everything trimmed, rounded over, filled, and sanded... maybe even primed. Also ordered the perforated steel grill material this morning. $55 for all 4 pieces, precut.