Remember this morning when I said I was close to gluing and clamping the front baffle? Yeah, I thought that was a funny statement too...
I came upstairs for a cup of coffee and my wife said she wasn't feeling well and needed to lay down so I was on kid duty.
Being a good husband I relieved her so she could rest and recuperate all day. Don't get me wrong, I love to play with the kids but I was keen on getting this box together before doing anything else. I WILL
get the first box glued and clamped up tonight.
Anyhow...mini progress update of all the prep work which needed to be done on the front baffle before attachment.
First, I precisely located where the wood screws needed to hit the thick areas of the internal matrix bracing
Per the construction plan, I am adding a limited number of screws around the perimeter of the box. I drilled 5/16" holes approximately 1.25" into the first baffle layer so the 2.5" exterior grade wood screw would have about 1.5" of purchase into the side walls of the box. I'll fill all these holes with wood filler once the front baffle is secure. A 5/16" is just large enough to accommodate the width of the 2.5" screw head
All predrilling finished.
Next, I trimmed off all the excess polyfill to a consistent 1.5" depth around the perimeter of the box for reasons I described in my previous post
I then laid the front baffle in position
This 1/8" drill bit is ridiculously long, but it's what I had on-hand which could reach the matrix bracing through the full 3" thickness of the front baffle to precisely locate the predrilled hole locations in top of the matrix bracing
Using the 1/8" pilot holes I had already drilled through the back of the front baffle, I drilled into the matrix bracing with this long bit to find the exact location I needed to predrill the bracing with the baffle removed.
With the final predrilling in the matrix bracing complete, I attached the polyfill with spray adhesive and cut out the dados. Not shown, but I obviously cut out the polyfill from the driver area as well.
So that's it. Everything is completely ready for the front baffle to be installed...I just need to find the time and energy after the nighttime routine with the kids.