HowieZ's T24 build

[howiez]

What do 2 fresh sheets of Arauco mean? Time to make some more BFM goodness.

I'm about to build a pair of T24's, 18" wide to hopefully have a more portable sub solution. My son has started taking the T48's and DR200's to parties on request. It's a struggle to load those monsters in his Honda Pilot. But, we can get 2-T48's 2-DR200's and an SKB rolling 6U rack in there with a little work, leaving both front seats empty for him and his girlfriend.

I'll be following the plans very closely this time, no crazy substitutions. My only caveat, is I'm making panel 8 square at the mouth instead of letting panel 7 run out there. I want to be able to put my stackable corner protectors there (albeit trimmed back to 1/2" thick) as seen in pictures on my DR200 mount. I suppose I could make a little scrap wedge of ply there to fill it in? I would oh so much like to use neo drivers for weight, but I'm hunting for a budget driver. You know me, I like trying things like GRS, Dayton, since these will never be used for pro. The better half has already warned me my hobby is expensive. I suggested I could take up hunting and fishing, buy a 30k boat and some gear...

Fresh ply (and the garage stack)

Flush mouth panel 8

Corner protector cut back for mouth

[Seth]

As usual, I look forward to your build blog. Putting the proverbial bag of popcorn in the microwave.


Okay... I'm ready!

[howiez]

I feel like I made some progress today, but not as much as I expected. I laid out one cabinet worth of 'nest' on a 4x8 sheet to plan my cut strategy (see my pix). I didn't have an assistant today, so I used my THT build platform on sawhorses as a makeshift outfeed table. I cut 41-1/4" off each sheet with a circular saw. After cutting two chunks like that with a circular saw and an edge guide, I could manage the remainder with the outfeed table. That allowed me a 24 x 24 side and a row of 17" wide panels, plus a little stock. My sheets seemed pretty square. Then I set my table at just under 24-1/8 and cut a strip on those small chunks across the 48". That left me some to clean up the factory edge. then I turned the piece and cut out the corner for a 24x24 side panel. Next I set the saw for 17 and some fuzz, leaving a strip i could cut panels out of and shave the other side off to clean up my circular saw cut. Then I ripped another 17plus off the larger remainder sheet for more panels. then I went back to the 24 and a fuzz and nocked the other side panel out. That left me a few 17plus pieces to cut out and scraps for braces. Then I set my saw for 24 and squared up all 4 side panels.

I started laying out the construction lines on all the side panels. This is where I ran out of steam. Like Bill mentions, I should have cut off a few steps. I'm trying to build the pair, so I setup the saw once and cut twice to save time. So i'm trying to pick my sides, good Arauco side out on both, and trying to decide if i make them the same or a mirror image. I had two panels all laid out inside, then started to transfer outside for a nailing guide. Then I thought, second side I probably will just clamp, so no layout needed. Then I went back to my 'pair' and thought I had one layout backwards, so I flipped it then realized I was on the inside and it's backwards anyways lol. I give up for today.

My CAD nest

Panels roughed to width, and sides finish size.

lots of layout lines...

[howiez]

Got the worst part out of the way. I HATE plunge cutting the access panels. I'm always worried the saw will jump or I'll cut too far. I used one of my laminated 2/4's as an edge guide to make the plunge easier (similar to what the plans suggest). I cut both sides to gut as much with my new Freud thin kerf 60 tooth plywood blade. Then I finished the corners with a multi-tool. They turned out pretty good, enough so that I can swap access covers and they fit reasonably well. Then I cut all the panels down to finished width and almost finished length. Had to break for lunch but I'm head back to start making angle cuts.

I HATE this part.

Swapped access covers to test fit.

Stack of panels.

[howiez]

Got most of my panels squared off to rough size. Got the finish size and angles on the first 6. Glued first two panels this afternoon. Here's a couple shots of my mockup to see where I could clamp. I decided I would only shoot nails in the interior on this cab, since it's no hurry to complete. I'll just glue a panel or two every day and force myself to take time!

Glue mock-up testing for square

[Clef's of Bass]

Howie, i love your 2 x 4 saw horse topper! I'm going to build one too.

Your build progress is looking great.

[howiez]

Howie, i love your 2 x 4 saw horse topper! I'm going to build one too.

Your build progress is looking great.

Thanks!

That was my THT build platform. I'm going to cut strips of 3/4" ply and laminate my own 2x4's (like my two guides in my glue up), and build another flatter/sturdier one. It's great, I take it down and stand it up against the wall when i'm done. I fold up my saw horses and tons of space is saved.

[howiez]

A little update, now that I'm to the glue phase, I'm slowed down to one step a day. Wish I had more clamps! I may shoot some nails at one point to put in successive panels. But this gives me something to putter with after work every night.

Got the first cab out of clamps and glued second, panels one and two. I had a square on first one, had it within a RCH of plumb. Now that I take the clamps off, she's a 1/16 to 1/8 out at the end. Maybe as I glue the next panels on, those will pull in. I didn't think to check the corner where 1 and 2 meet. I'll check when I unclamp the other in the morning. I also waited about 2 hours and scraped off excess PL with a sharp chisel. I couldn't do the same with cab 2, as I had a laminated 2x4 on one panel to flatten it a bit. Dang that Arauco can spring back when it's cut up!

a bit out of plumb at the end

a bit out of plumb at the end

second cab panel 1 and 2 clamped up

[Seth]

Looking great Howie

Don't sweat it, you'll be able to get that back where it should be when you put the adjoining panel in place and secure it.

[howiez]

Well it's more plumb now. I do feel like things are lining up very well compared to a Titan or THT build. Maybe I'm more suited to small builds. Maye I'll try a T30 next. I guess I left every panel a fuzz long, maybe 1/16" or so and maybe that accounts for the 15/32 thickness? After all, my CAD model is 1/2" nominal and laid out that way. Anyway, I have panel 3 and 4 on now and some blocks glued in for the screws. I feel like my driver hole was too close to the ends, so I just ran a strip all the way across to thicken it and give me driver screw bite.

CAB 1

CAB 2

[howiez]

A little more progress, not too many setbacks. I cut panel 3 to panel 6 braces a shade too narrow. I pushed them back a bit but tried to balance a bit of PL expansion vs panel 6 being weird. I'm still cutting each part twice, building both cabs side by side. I'm a 1/16" off on panel 1 at the mouth. the corner is off the line a fuzz and a 1/16 off compared to the plans and my other cab. I'm trying to wrangle it all back inline as I go.

Cab 1

Cab 2

Cab 1 panel 6

Cab 2 panel 6

[howiez]

A bunch of pictures, made some progress on the weeknights and this long weekend. Panels 6 through 10 and their respective braces installed. I try to glue one panel and let it cure 2hours and scrape. Then I let it sit one day. In the meantime, I cut the next panel to finished length, and it's brace to size and glue them together, using cab 1 and cab 2 panel pairs to clamp lightly. This gives me a decent brace when setting up that panel the next day.

Cab 1 panel 6 and y

Cab 2 panel 6 and 7

Cab 1 panel 8

Cab 2 panel 8

Cab 1 panel 9 and 10

Cab 2 panel 9 and 10

[Seth]

Dang Howie, moving right along and looking good

A little shared personal experience; I got tired of wrapping stuff I didn't want the adhesive to stick to in wax paper/plastic, so I tried using just the blue tape as a release barrier and found that it doesn't stick to PL and is much easier to use.

[howiez]

Dang Howie, moving right along and looking good

A little shared personal experience; I got tired of wrapping stuff I didn't want the adhesive to stick to in wax paper/plastic, so I tried using just the blue tape as a release barrier and found that it doesn't stick to PL and is much easier to use.

I did try blue painters tape on a build a while back. I think mouth braces. Someone here had mentioned putting tape along side the glue joint. Then peel it up at the 1-2 hour mark instead of scraping, and it comes right off.

It's near 100F here the last few days. I'm not doing much, even with a 42" barn fan my single garage space is stuffy. All panels on except 11 corner reflector. Time to work on flanges for the access holes, and maybe the corner reflector will get glued in tonight.

The pair almost ready for sides.

[Seth]

Nice to see it's already got the signature paint scheme