BillFitzmaurice.info

Dan_S wrote:It comes off the fingers easily too!

Maybe if you catch it by rubbing your fingers in sawdust before it dries. Wait until it dries.

Haha, very true! I was quick to clean it off, but I'm sure with a bit of setting time I'd have more problems.

I've seen that on the website that the original speakers used pioneer midbasses and MCM tweeters, yet the GR-Research ones listed in the plans are quite expensive (for good reason, I'm sure). I was wondering, are there any midbasses or tweeters that I can look at from MCM or parts express that might be a good comparison, except in the price department?

Dan_S wrote:
I've seen that on the website that the original speakers used pioneer midbasses and MCM tweeters

Both were discontinued. The GR are the closest I've been able to find in terms of sensitivity, which must be high to keep up with the sub.

Thanks for clarifying Bill, that's fair enough!

I've just glued on panel 2. Without long clamps I had to rotate the speaker and put weight on the back of panel one, so that it's "clamped" between it and the floor. Not the best initial join, but I'll fill the gaps and finish off the join once it's fully tacked in.

My first "schoolboy error" of this project is that I used a metal guideboard to secure panel 1. Reading the instructions on the PL tube it said that if you want to aid bonding of metals to mist the surface with water...so I didn't, as I didn't want it to! I came to it today, and it was stuck fast. I'm going to have to get a thin blade (like a shinto saw) to cut it off. Great! Time to get some wax paper!

This PL glue is a different beast to what I've used before - very different. It dries with a smooth and hard finish, whereas my previous glue wasn't anywhere near as resilient.

Last Friday I managed to get panels 3 and 4 on, and tonight I've put in the brace for panels 1 and 3. Progress is slow, but it's getting there!

I'm still undecided as to what to do about the guide board for panel 1 - it's still there, and I've not been able to remove it as yet. From what I've read, the general consensus is that once PL has cured, that's it!

My wife keeps suggesting I try applying some acetone to the joint to see if it'll separate. Is this likely?

Dan_S wrote:...I'm still undecided as to what to do about the guide board for panel 1 - it's still there, and I've not been able to remove it as yet. From what I've read, the general consensus is that once PL has cured, that's it!

My wife keeps suggesting I try applying some acetone to the joint to see if it'll separate. Is this likely?

Using a long, straight and sharp knife to cut the PL between the panel and the guide board. Work slow and carefully and you will eventually separate them. And then, invest in wax paper!

Dan_S wrote:
I'm still undecided as to what to do about the guide board for panel 1 - it's still there, and I've not been able to remove it as yet. From what I've read, the general consensus is that once PL has cured, that's it!

A multi-craft too works wonders.

+1 To the multitool...if you have a mernards near you the cheap Performax one works wonders....and yes I have used the Fien Multimaster....seriously the Pefromax is closer in performance the Fien would like to know. Also has a universal blade attachment for $5 so you can use any blades you find. Super handy tool when you remember you own it.

Thanks for the advice on the multi tool, I'll go and have a look for one! I already have a Dremel, so maybe there's an attachment for it...?

It would probably be more expensive than what's been mentioned though!

I've managed to cut and glue in panel 5 this evening. I received a mitre saw a week ago or so, so I had a chance to use the saw to cut panel 5 after my daughter had gone to sleep. It took more time, but it's nice to actually be able to do something!

I realised as I was ready to glue the panel in that I did a terrible job of squaring up panel 4, unless it moved after I'd left it to set. So, I've got a bit of gap filling to do, but it shouldn't be too difficult. I have one of those "orange triangle" squares that's being used to keep panel 5 at 90 degrees as the glue sets. Fortunately I had a plastic bag to hand, so that served as my wax paper

Dan_S, build a pair of these cauls in this thread http://billfitzmaurice.info/forum/viewt ... ul#p164595

Thanks Tom, I'll dig out some scrap wood for those W cauls, and hopefully make some this weekend!

The right angle setup in the previous post seemed to work though - everything came out square, and the square itself came off without any problems this time

I cut and installed bridge 3/5 tonight. I had to shave it down a bit using a rasp, but in the end it made a snug fit. I've used one of my F clamps to squeeze panels 3 and 5 slightly, so that they didn't splay as I pushed the brace in.

Panel 5 does stand slightly proud of the top of the speaker, so I'll have to shave that down too before I can glue panel 6 in.

After checking for any signs of light poking through the joins, I levelled off the end of panel 5 and glued on panel 6. I bought a 26" Stanley finish cut saw, and it cuts through MDF like butter, thanks to the new teeth and the long stroke in comparison to the mitre saw I've been using.

I misread the instructions though, and glued panel 6 to the ends of panel 5 and the side. I must have confused myself in a serious way as I made the top 14.5" wide, so there's a 1/4" overlap on each side for the top to rest on the side panels.

Fortunately, the "orange triangle" square came in handy again, as it has a 1/4" lip on one edge. As I glued panel 6 down, I clamped the square to the side panel, butting panel 6 against it, so that it was square, and recessed to that magical 1/4". Schoolboy error I know, but out of the multitude of mistakes it worked out

I'll do the same on the other speaker, so that the horn paths match.

On a completely successful note, I managed to remove the guide board. I had to use a small chisel to pry away at different areas of it, but finally it came off. It was stuck only in a couple of small areas, and so I basically had to tease the top couple of layers of MDF off in those parts, as the glue obviously wasn't going to give in!

Apologies for the lack of updates!

I've just glued on panel 8 tonight, after installing the braces for panel 6 (which I had to adjust for the extra distance) about a week and a half ago. Panel 7 and the brace I did last week, and this last weekend I made up panel 8. I had to add extra pieces of wood at the ends to make a 14" wide piece 15" just for those last few inches, but that wasn't too difficult

I definitely need some more clamps, and bigger ones too. The wood and paint pots seem to be holding their own, so once I've got everything squared up, 'locked' with some small fast clamps, and making absolutely sure that the wood doesn't creep over time, it's time to cross my fingers, and let it set!

I'll take a picture or two when I get the brace for 7 and 8 in, so that the 'snail shell' can be seen. Until then!

Dan_S wrote:
I definitely need some more clamps, and bigger ones too.

You could make some extenders such as in this link.... http://www.woodmagazine.com/woodworking ... xtensions/

http://www.harborfreight.com/hand-tools ... 92490.html

I really like these clamps. Cheap and light....I dont like most of the other clamps sold there...irwin is the way to go for others minus a couple spreaders and a couple 2' bar clamps. Also pipe clamps a couple rigid coupleplings and assorted pipe works good. I have all of these.and just use the right one for the job