Originally Posted by bdemarco
These look great! I was just hunting around the forum to see if anyone has already build the boxes that I plan to build (except I plan on building the definimax's). Do you happen to have a cut list? I couldn't tell if you did rabbit joints for more than just the left and right sides of the box. Also, did you only used one brace?
Once again, really cool!
The cutlist I used isn't terribly useful as I just put rabbet's and dado's everywhere like a madman
The bottom line is to get a box 14.5" wide, 26" tall, and 13.5" deep. Then laying Erich's front baffle over that gives you the final 14.25" depth.
For the record, if I were starting over I think I'd do (this is per speaker):
Qty 1 - 13 1/2 x 26 1/16 - inner baffle (cut 1/16 long to be flush trimmed at the end)
Qty 3 - 13 x 12 1/4 - 1 brace, 1 top, 1 bottom (brace is 13 x 12 if you forego the dado)
Qty 1 - 14 1/2 x 26 - back (3/4 wide x 1/4 deep rabbets around perimeter)
Qty 2 - 13 x 26 1/16 - sides (cut 1/16 long to be flush trimmed at the end, rabbets down one edge for front baffle to drop into)
This is more or less what I did, except I did a dado for the window brace (which I didn't care much for). You definitely don't have to do the rabbets around the back (or anywhere for that matter), I imagine most people would say it's a waste of time but I felt like it helped me get things square more easily. I do actually like the front baffle dropping in quite a bit though. I also did 1/4 extra on my overhangs which was WAY too much, 1/8 would've been much better and I'll go to 1/16 in the future.
I only did one window brace between the waveguide and the woofer. You could put one between the woofer and ports if you really wanted, there's room on the baffle, but I didn't feel like it was necessary. I used two vertical braces (I just used scrap material, you could use dowels) that were about 1" wide x 24 1/2" tall. I positioned these poking through the rear window brace hole, 1 on each side. You could definitely get fancier with the bracing if you wanted to but this seems to work fine.
Looking forward to seeing the Zephyr build, are you doing three or just L/R?