Instructions given by LTD02 and plan to follow
front face of baffle 32.61" x 28.5" (15 degree angle on across the top and bottom)
total height is slightly higher with the 15 degree angle
see image for driver and port location
top 11.56" x 30.0"
bottom 20.0" x 30.0"
2 sides [trapezoidal] 20.0" (at the bottom) x 31.5" (height) x 11.56" (at the top)
back 28.5" x 31.5"
Here is the Baffle wall
more instructions from LTD02 regaring Front wall
Cutting the pieces
If you look carefully, you can see the angled portion of the baffle on top. Since the baffle slopes back, the top rear of the panel is higher than the top front edge.
32.61" is the height of the front surface. The little nib that sticks up in the back will make the total height a little higher than that.
To cut accurately:
1. make a horizontal pass at 15 degrees cutting from left to right so the angle is going **under** the panel.
2. measure 32.61" and draw a line
3. make a horizontal pass at 15 degrees cutting from left to right again
I wrote down the plan on a piece of paper to follow.
Cutting the Back,Bottom,Top and Front were straight. Front has a 15 degrees cut on top as well. Wasn't hard to get. Circular saw allows to angle it. All I had to do was to angle it to 15 degrees and cut it. One thing to keep in mind here though is to to first cut this 15 degrees angle and then cut all other sides. Its much easier this way.
Sides were a bit harder and took a few tries before I got them right.
Next up: cutting the circles in baffle wall. This was was the hardest for me. I don't have the router so I had to make sure that do it properly using Jigsaw. I used the guide that I purchased for Jigsaw but when I tried it, it didn't work very well at first. To make sure I don't screw up the Front baffle, I decided to try the guide on a sample. Guide assured to move jigsaw in circular shape but I was having trouble using it properly. It was getting out of track slowly. I purchased a few blades from home depot to use with jigsaw and guess what, I broke 2 of them
. The reason was that I was forcing jigsaw to stay straight and I should have been forcing it to constantly stay in rotation. This forced the jigsaw to slowly get off the track and eventually the blade tilted enough and broke. Finally, I decided to put the guide away and try out purely using Jigsaw. I drew the circle (which was another challenge) and then slowly followed the line. While I was doing it, I realized that I had to constantly and very slowly rotate Jigsaw to follow the circle. Hmmm... may be I should have done that with the guide as well. After successfully cutting the circle, I decided to give another try to the guide and this time I decided to first draw the circle and the use the guide. Then I following the circle with guide on and there it is. Much better.
To draw the circle, I used a piece of wood. Pinned it in the center and made sure its length is equal to the diameter of circle and drew it.
Next challenge was to get the Jigsaw blade to the circle I drew. For that, I drilled a hole near the circle big enough to get the blade in and slowly moved it towards the circle and then angled it to follow the drawing.
After that, slowly follow the drawing. I used marker to draw since it makes it much easier to see and follow. I kept one hand on the back of jigsaw to constantly keep it in rotational angle.
Here is after cutting the driver space
Now comes the ports. I followed the same instructions. Measure, mark and then cut.
and finally here is the complete baffle wall
Next up: Glue the pieces and work on bracing