I cut out the circle for the terminal on the back...which took a few attempts. Thankfully I did some dry runs first. Parts express said the cutout was 2-7/8 but it's actually 3 inches. The backside has a slight bevel that starts at 2-7/8 but no way are you fitting the whole thing in a hole that size
I did some test fitting for the front pieces and before figuring out how to do it I took a chunk out of the back dado with one of my clapms
. Gonna have to fill that in later. When I got the two aligned I used some 1/8" guide pins to line them up. It works perfect. I only got the 4 port holes cut out. I need to make a little jig to cut the 18.5" hole for the driver since the jasper jig I have only goes to 18-3/16
I spent yesterday trimming up some pieces to make sure everything fits snug. Here is a pic of the bracing in the box with the back attached. I therw in one of the 180 sections of the ports so you can see how it fits
Some tips that I learned on this phase. If you need to line up pieces, use some dowel rods, they are awesome and help a ton.
Also, with the jasper jig if the drill hole on the piece you are cutting is slightly off don't worry! Despite using a punch one of the pilot holes I drilled was about 1/16th off...I had a bunch of crazy ideas cooked up (including cutting out a hole in another sheet and , template cutting it) but came up with a great solution:
Make the hole in the piece you are cutting a little larger than is necessary. Put the pin in the sacrifice piece (below what you are cutting) and align the center of the hole in the piece you want to cut. Clamp the pieces together. Now you can setup like you would normally and the jig will use the hole sacrificial piece to keep it centered.
Also, I don't have a spring loaded plunge router, the router I have you rotate the base and it locks in place at a certain depth. Locking this in place can cause it to move a bit and screw up the hole. A good trick I found (you will need a speed controller or a router with variable speeds), start on a low speed and plunge the router to the required depth and turn off the router. Secure it at it's current depth and turn the speed controller to the lowest setting. Turn it on and slowly build up speed until you are at your desired cutting speed and start going. I don't know if all routers will require this, but mine did since on startup, if you give it full juice it certainly torques a bit and will mess up the hole a bit.
Oh ya, something I recently discovered, not only were the two pieces of mdf I got 3/4" of an inch. They both weren't even the same thickness!
One was about 1/32 OVER 11/16 and the other was 1/32 UNDER 11/16...Thankfully I happened to go with the bigger one so I can sand off the small difference...but still annoying