Another T39 build

[CoronaOperator]

I was a little surprised to discover that my panel 8 is a half-inch too long! Double-checked the plans, and the Sketchup, and yep, panel 8 is cut to 39" early on, but measures out at 38.5" in Sketchup, so I guess I was supposed to trim it down. I didn't. I'll do it later.

A couple of beers and a chainsaw should do the trick!!!

[ctmullins]

Yep! The two official playthings of my state!

[ctmullins]

Not much to report - I've been doing the handle cutouts and the quarter-round; also trying to clean up my router slips with scrap wood and PL.

Also, Merry Christmas to me - brought home four fresh sheets of Arauco today! Not a moment too soon; I've been down to scraps on this build! I figure four more sheets will see me through the second T39 and both Otops.

[ctmullins]

Trying to make the most of the holiday weekend! Finished cleaning up the handle cutouts. Got panels 9, 10, and 11 installed too. Spreader clamps for the win, again!



Hooked two bar clamps together to hold panel 10 in position while gluing up panel 11. Does anybody else do ghetto things like this?



Used the Panel Jig to cut the angle for the mouth braces. So easy, thanks Bill!



I was also able to cut out most of the panels for the companion T39 from my newly replenished stash of Arauco.

And, in other news, I got a call from our bandleader today. Seems he's ready to relinquish the task of running sound while also being the frontman; says he wants me to share the job with our drummer. This is great news for me; now I'll finally have the chance to try out some of the excellent advice I've been soaking up in the Pro Sound forum here. He's still devoted to his too-big-too-heavy-90's-era reflex boxes, but maybe now I'll be free to center-cluster those 18" subs. Then in a few months I'll be ready to unleash my BFM rig!

[ctmullins]

Drilled for wiring - the long 1/4" drill bit is perfect here!



Also cut out the notches for the recessed casters that Leland sells. Love those things!

Also finished rough-cutting all of the panels for the second T39. Now I'm in a position where I can keep getting a few steps done each night.

Is there any way to leak-test before sealing it up with the second side? I used a small light to see if I could detect any gaps in the panel 9 joints, and I couldn't see any light from the other side. Might do that with a few of the other panels too. It's just so much easier to fix the leaks while the entire second side is open.

[ctmullins]

Had some time to make some progress today!

I drilled for jacks behind panel 9, right behind the driver.

I used the flashlight on my iPhone (nice and bright) to check for any possible leaks; thanks for your input everybody!

I ran a straightedge across the interior panels, looking for any that were too low or too high to allow a good seal with the second side. The area where panels 3 and 4 join was a bit high, so I sanded it down until it was flush.

I dry-fitted the second side to check for square; it wasn't, no surprise. Not too far out, though. I figured out where and how to clamp it so that it was square. Then I reached inside with a pencil and marked the joints; they were nearly perfect with my guide holes, lucky me!

Then, finally, the moment I had been waiting for! I generously applied PL to all panel edges, laid the second side down on top of the assembly, put a nail in the upper front corner, and used my long clamps to pull everything square. Then I went around the perimeter with nails, and then all of the interior panels. Just like the plans say! Have I mentioned how much I appreciate having such detailed plans? Thanks Bill!

I intentionally did not install the mouth braces yet, partly because I'm still trying to decide how to weight-relieve them, and partly because it made sense to me to install them after the second side, so that I know the cabinet is squared up.

Getting close to finishing!

[ctmullins]

Had limited time lately, but I have rounded over, sanded, primed, and just last night glued in the mouth braces. Duratex at the ready!

[ctmullins]

Building in fits and spurts....

Had to re-glue one of the mouth braces last night, so still no Duratex yet.

Started in on the second T39 though. This time, now that I've made one strictly by the plans, I'm going to deviate a little - I'm doing the panel 6 extension and panels 7 as one piece.



The cutout I will use for the driver anchor.



And the circular cutout on the baffle itself is used for driver access panel braces.



Limited time today and tomorrow (story of my life, but I do love my family!), but I hope to have at least a bit more progress to show in the next couple of days!

[ctmullins]

Panels 1 through 4 done in one session last night.

[ctmullins]

First coat of Duratex on cab #1.



I'm happy with my progress this weekend!

[ctmullins]

Panels 5 and 6, and their braces, installed last night.



i dry-fit the panels and marked the positions of the braces, then pre-installed the braces on the panel:



But I must have mis-marked the panel 4-6 brace, as there is too much gap on one edge. I filled it with PL, but I'll have to check it tonight. Worst case I'll have to reinforce it with another strip of wood.



I also flipped the first cab over and applied another coat of Duratex.

[Bill Fitzmaurice]

I dry-fit the panels and marked the positions of the braces, then pre-installed the braces on the panel:
But I must have mis-marked the panel 4-6 brace, as there is too much gap on one edge.

That's why I don't recommended installing the braces that way.

[ctmullins]

I guess I'm a "learn by doing" kinda guy....

[ctmullins]

4/6 brace seems okay - doesn't give when I tug on the free end of panel 6. Onwards...

6ext/7 combo panel glued in. I also glued the vertical flanges in place, holding them with small spring clamps.

[ctmullins]

Been a bit under the weather this weekend, but I did make some progress.

Got the horizontal flanges glued in. At this point my deviation from the plans ends.



Fitted panel 8 and its associated braces. I decided to skip the swiss-cheesing this time. It takes too long and doesn't really shed much weight.





Duratex on the first cab is nearly complete.

Also spent some time with my new Behringer XR18. Very cool little box o' magic!