This should finish up the Cheap Thrill phase of the build. I completed final assembly of the third cabinet today. Like the others, it wasn't totally without incident, but everything should be good.
I started by using some drywall screws to gently secure the XO boards to the bottom of the cabinet.
Then I stuffed some R13 I had laying around in there. I hope this is enough.
Erich's kits come with foam gasket tape, but at least in my case, only enough for the waveguide. I found that it's not terribly sticky, but it adheres pretty well if you stretch it gently - like electrical tape. I had a little extra, due to the stretching.
For the woofer cutout, I wasn't sure what was recommended, but I had some similar foam tape laying around, so that's what I used.
In the case of the first two cabinets, I temporarily laid in the drivers and drilled through them to prepare for the screws, then removed the drivers to clear out the dust and shavings, then connected and screwed down the drivers. In this case, I went ahead and connected, then drilled and screwed without removing - I just had to blow out the shavings. These next two images show the hiccups. The first is that the woofer is a little dented. I'm pretty sure it happened in shipping and I didn't notice until I went to assemble. I had to bend out the lip on the edge to make room for the head of the screw. Unless it buzzes or something, I won't worry about it. This picture also demonstrates a pointer I have for novices. As with seating any gasket, the piece is basically tight when the gasket is deformed enough to stop leaks. With your finger across the edge of the driver, you can feel the driver sit down into the tape as you tighten it down. Once it's flush or starts to get tight, stop driving - MDF is easy to strip. Sorry these are so blurry.
Here's the last assembly shot, which shows the last hiccup and my other tip. Here I had to use drywall screws to secure the waveguide. They were the same shank and thread, but have a flat head instead of the pan head that Erich supplied - but the heads are the same diameter, so the drywall screws still sit down inside the recess nicely. Somehow I had exactly enough in my shipment for three woofers and two waveguides - so four drywall screws and I'm in business. The tip is use a normal screw driver - never a power driver; again MDF is easy to strip.
Last bit here is that these are big heavy speakers. I tried to get the speaker to balance on the scale but couldn't see the numbers with the cabinet sitting on them (duh), so first is me without the speaker - a few pound less than I expected.
Then me with the speaker in my arms - special thanks to the Mrs. for taking the picture while I held the speaker over her head.
If I'm reading the scale right and doing the simple math right, each speaker weighs just over 60 pounds! Luckily they are small enough to fit through doorways with arms on either side, so they are manageable solo - bend at the knees
Team lift recommended for close clearance maneuvering.