Nova Monitor

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Edited by Jay1 - 5/28/13 at 4:22pm

Cut and flush trimmed using a dremel with it's circle guide attachment!

Gluing up some 2" ABS pipe for the port before I start gluing panels together.

Edited by Jay1 - 8/9/12 at 9:09pm

In keeping with the cheapo theme I didnt bother with cutting/routing/rounding an inner radius for the port. I drum sanded by hand with my dremel a rough radius, then smoothed by hand with 180. The ABS is 3/16" thick. It's minimal, but better then nothing and took 10 minutes. Got the sides and back glued up on one, dont have enough braces for both

Work on these has slowed considerably, but I've managed to make some solid progress. I flush trimmed all sides, then glued up the top and bottom panels. I've read threads recently on various forums bashing PL Premium for not curing (some have made a big deal after only 12 hours). I've never had a problem with it, but during this last use I definitely experienced the claims. The difference is, I know my tube was good so I gave it time, 3 days to be exact for it to fully cure. The temp had dropped significantly, and the humidity with it, so that's what I blame this whole fiasco on. Verdict is, dont rush with PL. After that cured I decided to add some bracing, which honestly isnt even need considering the box size and 3/4" ply.

I've got the front to back brace tied into the port with a line of PL, and there's another brace under the port tying into the bottom. I have a 45 degree angle brace I'll be adding to the top. I've really got to start thinking about bracing before I glue up the sides... Definitely getting extensive with the bracing on the center channel I'm doing next.

Got the boxes flush trimmed. I need to get some more 120 and sand these things down real good before I put a 1/2" round over on them. Hopefully I'll remember to pick up the 120 tonight.

Got a chance to work on these for a few hours today.

Sanded down then ran a 1/2" round-over bit. I guess I lucked out with my baffle width, as I dont think I could have got much closer to the woofer cutout. You can see the void issue I have here as well



This is on top of one of the cabs I should have been able to prime tonight, instead I'll be spending days fixing this crap plywood.



First application of bondo for my largest void. It'll most likely take at least 3 trys to fix it up


Of course I cant say when I'll be free to work on them again

I got the majority of the voids taken care of, but it seams like random areas keep breaking off. I'm going to try something new for myself, I mixed up water/wood glue and rolled a couple coats on with a paint roller. Hopefully it seeps in and seals/hardens the exterior plys. Not quite sure how it will act with the bondo'd areas? Guess I'll be the one to find out.

The glue/water worked really well, even over bondo. I only did one more application of bondo after sealing, I'm starting to get anxious to finish these. I drilled all the hardware holes then set up for painting.

All I had on hand was a can of the rustoleum primer, which I hate, but I really wanted to get this going tonight. Hopefully I'll get these top coated on tuesday.

Got these top coated! After they cure I can begin installing all the internal components, and hopefully have surround sound again this weekend!

I "scuffed/buffed" the primer with soapy water and a green scotch brite pad, since I decided to spray something other then flat I wanted the surface really smooth. I went with the krylon satin nickel this time, I wanted something similar to my wall color, but not as boring as egg shell white. They look pretty good from a couple feet, up close you can see all the voids I missed on the ply wood. Best thing about DIY is it only has to be good enough for me, which is why i didnt backfill and re prime lol.