Originally Posted by Mrkazador
The outer layer will sit on the baffle? How are we going to line up the outer baffle so the edges are perfectly sqaure?
The same way you would with any other baffle you'd install on the front of a speaker. On these, you'd put glue between the 2 layers, and then clamp it in place. I don't think it will be too hard.
Some people might prefer to use screws and pilot holes along with the glue.
I'm thinking about having the outer baffle cut about 1/32" bigger in both directions so the edges could be lightly sanded if needed. Or have enough of a lip to match up with some veneer that someone might add later.
CNC machines are accurate to 1/1000 of an inch. I've taped these boxes up and they line up real nice, but even the thickness of glue or PL adhesive could cause you to need some light sanding. Basically they can be lined up perfect, but if you run your finger over a seam, it could still need some very light sanding. There's no way around human interaction causing the need for light sanding when dealing with wood.
A clamp too tight, or not as tight as the next one can cause a seam to be off by about the thickness of your fingernail. There's no way around that. But sandpaper will knock that down in a minute. These will be far more accurate than things cut on table saws or other home gear.