15x15x60 TTLS no square cuts no clamps newb-build

[MTB goat]

15x15x60 Table Tuba build. total newbie here.

Only tools I have are an old cheapie craftsman circular saw and an antique 50 year old table saw. I see the importance of having all the panels the same width but the table saw did not make for exact cuts. I don't think the blade is square with the rip fence. So, I tried to make better with some 60 grit sanding. after 30 minutes of that I called it good enough. Tried to PL glue the first panel, I used many screws. I sure hope I am doing this correctly. there will be lots o pics. feel free to criticize or compliment. I'm not much for words but I can post pics.

[MTB goat]

some screws split some of the plies apart maybe I should have drilled pilot holes?

but here is the first....

[escapemcp]

+1 on the pilot holes. A combined drill/countersink may be the best bet/bit That way you don't have the PITA moment when the PL is drying you've screwed the screw home, but then realise you still need to countersink all the holes Must have happened to me on at least half the panels. It also means the depth of your screwholes is constant (and hopefully just a tiny bit shorter than your screws).


And just to check (so that the cab works as intended), you are using PL (or your local equivalent), right? I think the car in the pic has a US numberplate, so you have no excuse for not using the right stuff

Loving the crossed out line in the final pic of your first post (by where most people put their castors). Looks like you went the wrong side of the first line when allowing for the 1/2" stock. I don't think I have a single cab that doesn't have this particular 'feature'... one of them I only caught when the wood I had cut seemed completely the wrong size to fit within the lines I had drawn After realising my mistake it was an easy fix (can I call that a 'fix'??... probably not as it was more like just ignoring the previously drawn lines )

Keep the pictures coming. Having the guys on here double checking your work can save a whole lot of heartache and burnt wood (as long as you take the comments on board, and don't just ignore them - like a certain infamous (ex-)member used to do ). If comments are made, they are only made to help you build a better cab (or keep you safe). This is not a 'points-scoring' forum (thanks everyone )

[MTB goat]

I was sold on this design by this statement: "these are very easy cabs to build. Don't have a table saw? No problem, you can cut all the parts with a hand-held circular saw, and get perfectly straight cuts too."

Seems to me, you really need a table saw or some other real good method to cut all the panels as close as possible to the same size. otherwise there will be a leak when the final side is put on.

you are using PL (or your local equivalent), right?

Yes. I thought I was using too much but then I really didn't have too much squeeze out so I guess it was about right. I have never used the stuff before. Crap, I just realized I didn't cap it. I hope I didn't waste a whole tube drying out at home right now. what does everyone use to keep the rest of the tube from drying out?

That way you don't have the PITA moment when the PL is drying you've screwed the screw home, but then realise you still need to countersink all the holes

So are you saying those 8 screws I put in last night are now permanent? I was hoping I could remove them after the PL set up and then fill in the holes. I guess I will go to lowes and look for that countersinking bit

[sine143]

MTB, there are people on this forum building the subs with HAND tools.... I'll try and track down the thread.

make a saw sled, and the circular saw will do the job you need to do. My first 4 subs were built using nothing but a drill, a circ saw, and a router.

[MTB goat]

MTB, there are people on this forum building the subs with HAND tools.... I'll try and track down the thread.

make a saw sled, and the circular saw will do the job you need to do. My first 4 subs were built using nothing but a drill, a circ saw, and a router.

Well that makes me feel better. I have been reading a bunch of other build threads and DANG if some people don't have some serious workshops and talent.

I will have to look into that saw sled. I probably should have done that BEFORE I made all my big cuts.

[67baja]

Thought you had a huge problem when I first saw the brown bottle with the silver label - COORS LIGHT??? Upon closer inspection, it seems like your build is going to be okay after all.

You can remove the screws and fill the holes. PL adhesive is plenty strong without screws - just use screws to hold it together while the PL cures. You must remove the any screws along any edge you want to round over anyway. I would definitely suggest drilling a pilot hole for the screws though, and yes Lowe's has the countersink bits like what is pictured above.

When I built my first cab using only a skill saw and saw guide (from the plans) I made T pieces out of scrap plywood to space the guide equal and parallel for all my panel cuts. Hard to describe it in words how I did it. In theory it works perfectly, but in practice I probably had 1/8" difference from cut to cut.

Just put a 1/4" screw or bolt into the end of the PL to keep it from oozing and drying out. Oh, release pressure for the caulking gun first.

I'm digging what I see of that Jeep!

[Bill Fitzmaurice]

Seems to me, you really need a table saw or some other real good method to cut all the panels as close as possible to the same size.

You do. It's called a circular saw sled, which the plans say you should use. They show a picture of one in use, along with how to use flat and right angle jigs to get perfect joints with no clamps.

[ncgrove]

I've been using one of these for my rip cuts and I've found they work pretty well:

http://www.kregtool.com/store/c48/saw-a ... -cuttrade/

[MTB goat]

Seems to me, you really need a table saw or some other real good method to cut all the panels as close as possible to the same size.

You do. It's called a circular saw sled, which the plans say you should use. They show a picture of one in use, along with how to use flat and right angle jigs to get perfect joints with no clamps.

I just re-read / skimmed through the entire directions again and the only place I can find that mentions or shows a picture of a circular saw sled is on page 14 for use in the trimming of panel 8. The jigs, yes it has that, and I did use something like that to align the panel before screwing it to the side. but I only see any notes about a saw sled at the end. maybe I was supposed to order the jig plans also? Please go easy on me, I am just a rookie. I read that a table saw is best to use for making all the panels at the same time, which I did... but the saw is old and the fence is not good. I did the best I could.

[MTB goat]

Thought you had a huge problem when I first saw the brown bottle with the silver label - COORS LIGHT??? Upon closer inspection, it seems like your build is going to be okay after all.
..............................

I'm digging what I see of that Jeep!

It is for sale if you are interested!

[Bill Fitzmaurice]

I just re-read / skimmed through the entire directions again and the only place I can find that mentions or shows a picture of a circular saw sled is on page 14 for use in the trimming of panel 8.

Page 2 of the current plans: Cutting the cab parts and assembling the cab is much easier using the jigs, guideboards, circular saw sled, cutting table and other aids contained in the Panel Jig plans. If you don’t have the Panel Jig plans you should consider getting them before starting your build.

[MTB goat]

Bill, I hope you are not taking any offence to the title of this thread or my comments. I was just trying to make light of my lack of skills and tools available. I'm sure I can make it work.

And so you understand that to a newb like myself, the instructions read as:

"Cutting the cab parts and assembling the cab is much easier using the jigs, guideboards, circular saw sled, cutting table and other aids contained in the Panel Jig plans. If you don’t have the Panel Jig plans you should consider getting them before starting your build."

The above "much easier" to me doesn't sound like I "must" or I "should" ...sorry. I don't want you to get a headache from banging your head against the wall.

[67baja]

"Clean 1 Owner" "All Highway Miles" and my favorite "Adult Owned"

[MTB goat]

Super proud of myself tonight! So, I have this router I used once over 10 years ago, but I thought I gave it away to someone. After digging around in storage, I found that I still have it. After reading various build threads and doing some online research, I made my own circle jig out of some plexiglass scrap that was laying around. worked like a charm!