BillFitzmaurice.info

As outlined in a couple of other threads, my first and biggest mistake was to use AWP marine ply, which is very stiff and strong, but also very heavy.
It also had a bit of a "pullups" issue, as can be seen here.

Handle and jack plate cutouts were done with my router's template follower and some pine offcuts.

I used the same system to do the vent cutouts.

I made a perspex jig to do the driver cutouts, since my router didn't have a circle jig. Since the position of the centre hole is critical, I made a test cut first to check my measurements!

As discussed in another thread, the glue I chose was too runny. If you ever find yourself in this situation, oven paper is your friend!
I also had to adjust the width of the baffle, and I have mounted my hand sander (using dowels - removable) to a sheet of MDF.

In keeping with the Jedi theme of this esteemed website, <gestures> "these are not the clamping images you are looking for"!

The bracing was clamped in an ever so slightly more legitimate manner

When removing some of the bracing screws, the glue had gripped them so firmly that they sheared right off. Fortunately, this didn't happen on any of the edges I intended to round over.

I pressed the damping foam down on the bracing, then turned it over and marked the temporary indentations before they disappeared.

Attaching the back, being deliberately generous with the runny glue to guard against leaks.

I used the same perspex jig to keep the router level when doing the roundovers.
The "inset" baffle presented a problem, as the edges that extend past it are not thick enough to support the roundover bit's guide wheel.
I therefore had to "pad it out" (and level everything) so that a roundover could be cut on the protruding sides, top and base.

I decided to build a grille standoff, which I don't think I would do again.

The magic of Duratex is that someone as obviously green as myself can get such a brilliant looking result!
I brushed on the first layer, sanded it, then put on two more with the roller.
As the Hobart summer was as unreliable as ever, I used the back my car as a curing oven.

I found a sheet metal workshop that sold me some perforated metal at a very good price, and cut to size.
I sprayed it with metal primer, then red enamel. This stuff forms a fine red dust that gets everywhere!

I bought some aluminium bar to frame the grille, and cut it to size with a hand hacksaw.
I went for the brushed aluminium look, at first with an actual brush but then found that sandpaper gave a more uniform result.
Finished off with a sprayed layer of clearcoat.