Originally Posted by Ricci
It is really not as hard as it seems at all. You have to remember I originally tried to make this a kit to be cut on a cnc and then lock together perfectly. Luke has it right... Forget all of that to the umptenth precision on the measurements and the dado's etc...It is really not that hard...I'm not surprised most cab shops won't touch it though, too much work on something they are unfamiliar with. I mean every panel has exactly what it should be and it is not that hard to put together. It is just not worth it for them to fool with it when they can just build another kitchen cabinet or table.
1. You cut the 2 side panels and mark out the path on one. (This is the hard part.) Everything else stems from there and is built upon that panel.
2. Every internal piece from there except for bracing will have the same 22.5"-22.6" width. (exactly what is not important so long as they are the same. )
3. Cut the length of each panel followed by the angles on the ends of the panels somewhat close then just make sure they are centered on the path layout and glue and screw the **** out of them. (if you are 1/4" off on your length of the bend panels it won't amount to anything acoustically. Don't worry about perfection.
4. Use butt joints for everything if you want.
5. Start from the driver baffle and internal bend panels and work your way out. Add bracing as you go. It is bracing it doesn't have to be perfect. It is bracing. PL the hell out of it and screw em in if possible. Get crazy put extra in...Whatever just don't block the air flow. The edge of every brace should always be in the path not the side.
6. Continue with the rest of it.
The hardest part will probably be the driver access panel but it is not that difficult with a decent router and jig. It doesn't have to be exactly that size just get it where your driver fits in. Hell you can just jigsaw cut a big hole and scab a whole other piece of material over the hole if you want.
Again this is being way over thought. The critical component is getting the horn path correct. I can't stress that enough. That is the main key thing. After that it should be easy to go piece by piece. The rest is just building it solid, sealed up and well braced.
Yes more bracing was added towards the end. Actually I am revamping the design a bit and simplifying it a bit and adding even more bracing. Instead of a center brace internally I am using 2 equally spaced braces on each internal panel. All except for at the mouth area.