Thought I'd use this post on the first page to list out the tools used, tips and "lessons learned" etc. as I go through the build being my first time. I'll update it as I go along.
Note, this obviously was not a "how can I build a subwoofer as cheap as possible to beat out X commercial sub", i.e., I didn't try to build the sub with 1 or 2 tools, bought a relatively expensive amp, did some roundovers etc.
Tools/materials Used:
3/4" Birch Ply
1" Dowel rods (for bracing)
Bosch 1587AVSP-1 Jig Saw (great jig saw once you learn the blade release mechanism and comes with several blades)
Bosch T244D TShank blades (for the round over cuts)
Battery Powered Drills - I actually have 2 plus an electric drill. It's great to have more as you can use one with a drill bit to drill pilot holes (see tip below) and another to drill the screws in. Obviously not required, but hey, I had them so ....
Various drill bits (buy one of those cheap wood drill bit sets)
RYOBI Router and 1/2" Roundover bit - only used for the roundovers, though could have used for the circular cuts. This router came with a bunch of bits (borrowed it from my father in law)
Husky 55" Saw Guide - GREAT tool for the jig saw, saved me numerous times!
Black & Decker Mouse Sander (all I had) and numerous sand grits (80/120/150/180/220)
320 Finishing Sanding "sponge"
Titebond II glue and Lepage Wood Glue - used both, but mainly the Titebond II as it had better initial tack which helped out at times.
1/2" Chisel - for recessing the Terminal Cups
Knife/Blade
1" deck screws (for screwing in internal wood blocks which were used as guides when gluing)
Square
Work bench - mine wasn't the greatest as it was too small and the handles were annoying (it's some Fatmax bench that doubles as a trolly). I really don't see how anyone gets by without one though!
Level
Wood filler
1" Spade bit (to recess the dowel rods into the inner baffles)
#8 Wood Anchors
2 Large bags of poly fill from Fabric Land (5lbs each) - $29 each
Lessons Learned:
Jasper Model 200 Circular Guide - Grrr ... doesn't fit the RYOBI router even though it says it does, and can't return the darn thing!
Practice, practice, practice EVERYTHING on scrap pieces of wood if you are a first time DIY like me. E.g., using the round over bits.
Drill pilot holes before putting any screws or anchors in. Repeat after me "Drill pilot holes before inserting screws into wood". Say it 10 times. Great to have 2 drills for this reason.
Don't do any roundovers until you've glued most pieces on as in my case I noticed I was about 1/8" too large in terms of width (which was okay as if I was too short it would be trouble!) and having already cut the roundover it was a bit more of a pain to shave this off and redo the roundover.
When gluing - keep a wet rag by you at ALL times and a flat head screw driver to help clean out the glue. Clean out the excess glue immediately (don't wait thinking you'll just sand it off!).
Wood Anchors - thank you Joe for that tip ... very easy to drill into the wood. MAKE SURE you drill a pilot hole first though and put them in with a screw driver, not a drill, to try and prevent the wood from breaking.
Buy square terminal cups unless you're confident in your ability to make circle cuts. I started out with circular ones and ended up buying square, way easier to work with and easy to chisel into the wood to reset it a bit.
When staining, MAKE SURE you wipe off excess stain after 10 minutes or so per the instructions. Leaving it on just causes headaches!!
