First BFM Build Odyssey: Tuba 60

[Joman116]

Hey Folks

Been a lurker for over a decade, started posting last year.

Finally started my Tuba 60 build, 20" wide with Eminence Lab 12 speakers. Will start with 1 and see how it goes.
I own qty 2 Titan 39's right now.
Plan on powering the Tuba 60 with a QSC PLX 1802. I should be able to run 1 T60 on each of the 2 channels ..

Got most of the screw etc hardware already from speakerhardware.com.
12 sheets of baltic birch 5' x 5', quite a few tools. I am handy, but new to woodworking.

Few days ago I ripped the 5' sheets in half for the side panels first, using a table saw. They're a bit off by maybe 1/8 to 1/4 of an inch. That an issue? I assume when build is done, I can use a router to flush the edges, alongside sand?

Today I practiced making some of the right angle jigs. Struggled alot on my first one. The plywood splitting due to no pilot hole/not perpendicular. Then switched to brad nails, there is a technique so you don't blow through the wood..shoot it parallel to the bottom piece. Videos and practice got me better at it. It;s close to 90 degrees..may be off by a degree or 2..I hope thats not a deal breaker.

In one of the pics you will see I used "Loctite PowerGrab All Purpose". I do NOT plan on using this for the actual panels (I have the Loctite PL Premium). I just didn't want to open the loctite PL premium for such few pieces today..close it..and then opening in a week only to find it dried up. Any advise on storing loctite PL is appreciated!

I will make a total of 3-4 right angle jigs..then move to cutting the 20" wide panels..then start my drawings. I need to square up my table saw..some of the measurements are 1/4" off. Hopefully next update by end of this week...

Getting CLAMPS was a GODSEND..man these are a requirement..making life alot easier! Enjoy the pics and comments welcome! It's going to be a long journey and need all the help I can get.

[DaveMacKay]

Good luck with the build.

[shawn_g]

Looks like a good start! It's ok for the side panels to be a bit oversize if you have a flush trim bit, but it's a good idea to make sure your first panel that you draw the layout lines on is as close to perfect as possible or at least be aware of the discrepancy so you can compensate when drawing the lines. 1/4" short could be an issue depending on the panel in question. 1/8" here and 1/4" there start to compound off of one another and can make things difficult, so I'd recommend getting your table saw dialed in before you go too much further. The PL expands to fill small gaps, so don't worry too much, but do your best to get accurate cuts and keep everything square.

PL keeps for a pretty long time; at least a month or more after opening. I put a nail or screw in the end to keep it from oozing out.

Good call on getting clamps!

[Seth]

I've used an inexpensive secondhand jobsite style table saw for my builds and the fence is not accurate or repeatable. So, I set up every cut by measuring from the fence to the blade tip on both the front and back side of the blade to the fence while making sure to measure from the blade tip nearest the fence (most tips I've seen, every other tooth is offset to one side or the other with a different cutting edge angle). Adjust the fence, lock it down, measure again, adjust if needed, give the blade a spin, and measure again from a different portion of the blade incase the blade isn't exactly true, making sure to use the measurement that will allow a little extra for me to make a second clean up pass if need be. It's a lot of measuring and adjusting and I should just get a better saw, but it works well enough.

Buy disposable gloves and wear them when working with PL. To store my PL between uses, I put a finger of one of the gloves over the tip and use masking tape around the tapered portion of the applicator tip to create a fairly air tight seal that's easily removed, replaced, and stays put between uses. Works fairly well for me. Won't keep it forever, but I've been able to pick it up and use it a month or so after it's previous use. It cures with the moisture in the air, so basically anything that will keep the tip sealed should work. I intentionally use masking tape because it doesn't stretch and basically creates a tapered casting of the applicator tip. Although, something like electrical tape, applied without too much stretch, but just enough... might create a little snugger fit and seal. Maybe I'll test it on my next tube.

Also, in the plans it might say to use wax paper to keep PL from sticking to certain parts. I've found that PL wont stick to the blue painters tape and it's much easier to just put down a strip or two of tape where needed than it is to cut-out and affix wax paper in place.

Good luck with the build!

[Joman116]

Good luck with the build.

Appreciate it!

Looks like a good start! It's ok for the side panels to be a bit oversize if you have a flush trim bit, but it's a good idea to make sure your first panel that you draw the layout lines on is as close to perfect as possible or at least be aware of the discrepancy so you can compensate when drawing the lines. 1/4" short could be an issue depending on the panel in question. 1/8" here and 1/4" there start to compound off of one another and can make things difficult, so I'd recommend getting your table saw dialed in before you go too much further. The PL expands to fill small gaps, so don't worry too much, but do your best to get accurate cuts and keep everything square.

PL keeps for a pretty long time; at least a month or more after opening. I put a nail or screw in the end to keep it from oozing out.

Good call on getting clamps!

Thanks for the input. Aligned everything today..looks to be OK!

I've used an inexpensive secondhand jobsite style table saw for my builds and the fence is not accurate or repeatable. So, I set up every cut by measuring from the fence to the blade tip on both the front and back side of the blade to the fence while making sure to measure from the blade tip nearest the fence (most tips I've seen, every other tooth is offset to one side or the other with a different cutting edge angle). Adjust the fence, lock it down, measure again, adjust if needed, give the blade a spin, and measure again from a different portion of the blade incase the blade isn't exactly true, making sure to use the measurement that will allow a little extra for me to make a second clean up pass if need be. It's a lot of measuring and adjusting and I should just get a better saw, but it works well enough.

Buy disposable gloves and wear them when working with PL. To store my PL between uses, I put a finger of one of the gloves over the tip and use masking tape around the tapered portion of the applicator tip to create a fairly air tight seal that's easily removed, replaced, and stays put between uses. Works fairly well for me. Won't keep it forever, but I've been able to pick it up and use it a month or so after it's previous use. It cures with the moisture in the air, so basically anything that will keep the tip sealed should work. I intentionally use masking tape because it doesn't stretch and basically creates a tapered casting of the applicator tip. Although, something like electrical tape, applied without too much stretch, but just enough... might create a little snugger fit and seal. Maybe I'll test it on my next tube.

Also, in the plans it might say to use wax paper to keep PL from sticking to certain parts. I've found that PL wont stick to the blue painters tape and it's much easier to just put down a strip or two of tape where needed than it is to cut-out and affix wax paper in place.

Good luck with the build!

Great tip on using blue painters tape. Going to grab some tomorrow.

Today I was messing around with cutlist optimizer. Arranging for the rough cut panels. I am hoping to do the panel rough gets complete before the end of the week.

[Joman116]

Started cutting some panels today, about 30% done. Definitely needed a second hand for these larger panels to be cut off the table saw so I had to call on my father.

A table saw definitely made things easier, I couldn't imagine doing this with a circular saw I feel like it would be Messier and take longer. Hoping to finish the panel rough cuts by Sunday.

[Keryn O'Shea]

Take your time & enjoy the build mate, it'll show in the results.

I couldn't imagine doing this with a circular saw I feel like it would be Messier and take longer.

With a cutting table & zero clearance circular saw sled (in the panel jig plans), breaking down a full sized sheet accurately solo is a breeze, taking the next step to a track saw & two tracks has you cutting angles the full length of the sheet (without having to calculate distance from the cut line) & also smaller parts like CD horn diffuser brackets easily.
Table saws are great, a while ago l had a sliding table panel saw, but unless it was set to perfection, long cuts were inaccurate. If you have both, track saw for the long cuts & table saw for the smaller peices with greater safety.
It's all personal preference, just mentioned this for readers possibly thinking the circular saw & sled isn't up to the task.

[Joman116]

Take your time & enjoy the build mate, it'll show in the results.

I couldn't imagine doing this with a circular saw I feel like it would be Messier and take longer.

With a cutting table & zero clearance circular saw sled (in the panel jig plans), breaking down a full sized sheet accurately solo is a breeze, taking the next step to a track saw & two tracks has you cutting angles the full length of the sheet (without having to calculate distance from the cut line) & also smaller parts like CD horn diffuser brackets easily.
Table saws are great, a while ago l had a sliding table panel saw, but unless it was set to perfection, long cuts were inaccurate. If you have both, track saw for the long cuts & table saw for the smaller peices with greater safety.
It's all personal preference, just mentioned this for readers possibly thinking the circular saw & sled isn't up to the task.

Yes definitely personal preference. Space was a concern for me and I felt like I didn't have the patience to make that panel jig.

[Keryn O'Shea]

Space was a concern for me...

I get that, it needn't be full sized, they can be stored elsewhere or used as an assembly/work table also

I felt like I didn't have the patience to make that panel jig.

For best results, patience is the key.. channel your inner Zen master

It's going to be a long journey and need all the help I can get.

Take it slow, there's no deadline is there?
I used to try to build cabs quickly.. just wanted to hear them, but after pulling my pants up many times, l've learnt to cruise along & take the extra time when needed, it's worth the effort mate.