Back in the basement tonight, I got a little light sanding done on the ceiling, in preparation for a second coat of joint compound.
I've also been working on making sure I've got everything in order to build my Cheap Thrill cabinets. A new table saw blade and some wood glue should get me there, once I get some MDF cut down. I'm going to just copy what I posted over at diysoundgroup so that it will be here for my reference and in the interest of both having a complete record here as well as soliciting any feedback you all may have.
This may not be very useful to a lot of people, but I think it will get someone started to at least see how I've laid this out. If anyone sees any problems coming, please don't hesitate to speak up. This is my first build since cub scouts (pinewood derby anyone?). I don't have a lot of sophisticated tools or a truck to carry full sheets of MDF, so I've tried to simplify this process. I have 4 30" clamps, a table saw, a circular saw and assorted hand tools, but no router or anything fancy like a band saw or even a jig saw.
I started with thinking through what the process will be like. I read a few threads around here and there, and decided that I would try to assemble the top, bottom, and sides, with the braces to help hold them square. Then I would come back and secure the baffle and back. Using butt joints only, here's a basic (not to scale and without braces) image of the way the top, bottom, and sides should fit together.
Based on those joints and the description of the cabinet dimensions (17.25 wide, 26 tall, and 16 deep) I figured the dimensions of each piece. That lead me to this list:
- Baffle/Back 17.25 x 26 x .75
- Top/Bottom 17.25 x 14.5 x .75
- Sides (x2) 14.5 x 24.5 x .75
I'm building three, and of course the baffles come from Erich, so I need three backs, 6 sides, and 6 top/bottom pieces. I laid them out in sketchup to make them fit together in a cut sheet. I'm sure this is not the most efficient use of materials, but it will work for me very well. I've built in a little slack to account for the kerf. Did you know that MDF is sold in sheets 49 inches wide by 97 inches long? I had no idea.
Here's the key for the labels in the cut sheets:
Backs - A, B, C
Sides - D, E, F, H, I, J
Top/Bottom - K, L, M, N, O, P
The braces are not labelled, but there are enough for two horizontal and one vertical in each cabinet. I'm not sure about the profile of the braces, but I think what I've drawn here will work. I wasn't sure how deep they would need to be - the way I've got them planned, they will all lay against the back and reach toward the baffle 9 inches - should they be deeper? I'm not sure how I'll make the cuts, but I'm not concerned about winning any beauty contests. If there is a better way to design the braces, I'd love to hear some tips.
You'll notice that I've marked several cuts just to break down the sheet into small enough sizes to fit in my VW. I'll have the guy at Lowe's do that. There's enough excess in the pieces that a half inch or more won't be a problem.