Backyard Box Building - The Build
Hi all at last I am ready to start building my final solution speakers. These will be a kind of L300 clone. This is a project that I have been fermenting for some time ie. about 25 years. I first heard L300s way back in the 70's and the sound signature stuck with me ever since , like an itch you cant scratch.
I know there are bigger and better monitors but space considerations come into the equation also.
The purpose of this thread is to create a step by step guide to cabinet building using the minimum of tools and shop facilities, in other words the simplest easiest way that anyone with moderate skills can achieve a good result.
My project carries some quirks in that I am going to emulate the L300 cabinet but with different dimensions , hence the rounded corners will require more work than a standard rectangular box, however the build methods remain the same for both.
I would like this thread to remain clear of comments in order that the process is easily followed by anyone who cares to have a go , however I am open to any input along the way.
To that end please post comments and input on the other thread ' Backyard box building ' and quote the relevant page / post number.
I will also be calling on the expertise of the gurus at a later stage but that will come along as the build progresses. Here we go-------
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Lets make a cutting guide / Straight edge
The Gods of plywood are kind enough to supply their product with a very straight edge as standard , so we can use the edge of one sheet to guide the saw. The width of this is not important as long as it is not too skinny in which case it will tend to bow as you run along.
Say hello to our friend for today Mr RIPSNORTER.
Take care to mark up your cut evenly at both ends so that the remainder of the sheet is not skewed. 5-6" is plenty. Note the very essential SOLO Clamps
Cheap and effective the best ten bucks you will ever spend.
Set the saw depth to be just a little more than the material you are cutting say 1" for 3/4" material
Last pic , now we have a guide.
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Now we are ready to cut in anger
With our brand new straight edge we can now start to cut the material for the cabinets.
We have to allow for the offset of the saw blade INCLUDING the kerf or saw cut itself. As you can see in the second pic that offset is 42mm or 1 5/8" so this amount will need to be added to every size.
In this case we need 15 3/4" so add the 1 5/8" and that is your figure.
I'm actually doing this in metric and the numbers are 400mm plus 42mm.
BUT !!
we also add an extra 1/16" or 2mm because we are going to clean these panels up to a dead size at a later stage hence I am adding 44mm or in imperial 1 11/16". Remember that that figure is for MY saw with that particular blade so you will need to establish a figure for your own tool.
BUT !!
you must add on that extra little bit but no more than 3mm or 1/8"
So we now clamp up the guide and check your measurements TWICE
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Now the Baffles and Backs
Same as before always check your sizes and add on as before.
Pic 2 A little taste of what is to come.
Pic 3 The completed bundle. The two odd bottoms are marked
Now we are moving on to the real deal
From now on we are in the territory of Mini L300 with all the details.
Thus far I hope I have shown how with just a few tools that an acceptable level of box construction can be achieved.
If you go back and review what has been used so far we have
1 Ripsnorter
2 Good 1/2" Router
3 Tape measure
4 1/2 shank straight flute cutter for the router
5 1/2" guided trim off cutter for the router
6 Hammer
7 Sash clamps or ratchet straps
Not much really. :)