4 x T48 24" & 2 x T48 18" ... finally!

[DJ.LJ]

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.

[Grant Bunter]

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.

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...

[DJ.LJ]

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

[DJ.LJ]

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.

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Trimmed all panel 1s then drilled out all the dowels from side to panel 1.

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Used dowel jig for the panels. That is it for today. Hopefully glue those up tomorrow!

[DJ.LJ]

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.

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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.

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[DJ.LJ]

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.

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Then I marked all the panel lines onto the side and pre drilled some holes for holding the panels in place when assembling.

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I was able to PL all the panel 1's easily with the dowels.

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[DJ.LJ]

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.

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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.

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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!!

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These are all my pcs for the DR 250s waiting to be put together... it will be done after these!

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[Bill Fitzmaurice]

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.

[DJ.LJ]

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.

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[DJ.LJ]

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

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

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[DJ.LJ]

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

Today I finished up the panel 3s and panel 4s.

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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.

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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.

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[Grant Bunter]

Looking good so far!

[jimbo7]

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

[DJ.LJ]

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.

[DJ.LJ]

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.

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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!

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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.

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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.