DIY Sub - Started Today, Finally!

[dyazdani]

I posted a while back about starting a RL-p15 based sub. I finally got around to getting all the parts and pieces I needed to start on the enclosure.

Here are a few pics from today.

First, I constructed a sawboard to help me cut the MDF panels to a manageable size. I am amazed at how accurate the thing is after you get accustomed to using it. I didn't even plug my table saw in today!



I cut most of the pieces, the wall thickness will be 2x0.75 in. I cut enough to build most of the box except for the front (driver recess) and one top piece so I can put in the braces before buttoning her up.

Here's the first joint! I got some clamps off of eBay, they didn't turn out to be as nice as I'd hoped, but they were cheap. Seem to get the job done so far. Of course, I had my trusty corner clamps there for extra security.



Here's a close-up of the joint - a little blurry (sorry). The joints are nearly perfect over the entire length or the piece, not bad for only using a circular saw.



One more pic from a little ways away, death machine in the foreground :T



I took about 2 hours to clean out the carport so I didn't get as far as I'd hoped. I'm going back out now to get another side or two going.

More to come...

[steve nn]

Looking good. Let me take a wild guess here...your going to paint your new sub yellow right?

[dyazdani]

Yellow and black stripes, it'll be called the Bumble Bee :W

I was able to get to most of the "outer" box tonight. Have to double up on 3 inner faces, rout the driver hole, glue in the window braces (2), and I'm basically good to go.

[chasw98]

Excellent start, congratulations. You will want to move the crotch rocket out of the way when you start routing! (MDF in intakes? bad)

[dyazdani]

Excellent start, congratulations. You will want to move the crotch rocket out of the way when you start routing! (MDF in intakes? bad)

Yeah, I always roll it out into the driveway while cutting/routing. I'm going to attempt the driver hole after work if I have time. I need to make a practice run first...

[ThomasW]

I'm not sure, but I think the box is going to change the balance and handling when strapped on the back of the bike...:wink:

[dyazdani]

I'm not sure, but I think the box is going to change the balance and handling when strapped on the back of the bike...:wink:

The way it is going, the box will weigh as much as a person anyway. So it'll be like riding two-up. :lol:

[dyazdani]

Routed the holes for the driver and attached the baffle. I am going to add a layer of regular plywood on the inside to have a better medium for T-nuts.

I have to double up a couple of walls, rout a patch for the binding posts, and add the two braces.

Now it's finally taking a decent form...

[Glen]

Great pictures :T Looks like you've got a real nice spot to work there too.

[dyazdani]

Great pictures :T Looks like you've got a real nice spot to work there too.

It's a decent space, I just park my truck out in the driveway and use the carport for a shop. It has plenty of room, I only have a small table saw and it has casters, so I just roll it out of storage. Clean-up is easy too, a leaf blower sends all the little dust particles flying down the street :lol:

The only time I can't use it is if it's rained hard and the humidity is very high. The concrete sweats and becomes as slick as ice (it's polished).

[dyazdani]

Not as much progress today as I'd hoped, took longer than expected. I cut the first window brace (man, that takes time). I also double up on part of the remaining walls, making a slot for the brace. I haven't glued in the brace yet, I still need to rout out a spot for the binding posts.

The roundover bit on the brace just about covered the world with dust :E



I'll put another brace about halfway between the one in the pic and the back wall. I would have liked to even them up, but I didn't feel like taking a chance and putting a brace in that surrounds the driver too closely.

I also started to make a plywood ring to put on the baffle. That will create a better surface to install some T-nuts.

Another shot...

[chasw98]

Looks great! Don't forget to caulk it with the top off. It's a lot easier that way.

[dyazdani]

Looks great! Don't forget to caulk it with the top off. It's a lot easier that way.

Yep, been there, done that - not cool :M

I would have liked to fit an extra brace in there, but oh well. It's already very sturdy (and heavy :T ).

I should be able to finish the bracing and seal it up tomorrow. I still have to order the driver, whenever the wife gives the OK. :roll:

[borderdad]

If you need more clamps like those check Harbor Freight. I got 4 36 inchers for about 9 bucks each. They look just like yours. Box looks great.

[steve nn]

Very nice...it's looking good.

[dyazdani]

If you need more clamps like those check Harbor Freight. I got 4 36 inchers for about 9 bucks each. They look just like yours. Box looks great.

I got 6 of them off of eBay for $10 plus shipping. They were not exactly what I expected, they looked like regular bar clamps in the stock photo of the ad. That said, I didn't really expect much for $2 clamps.

They actually work quite well. The only drawback is that the "feet" ??? are not very long so if I have to reach, say over another clamp, I have to go MacGuyver on it and use some extra wood.

[dyazdani]

A little closer, got one brace installed, the other one is ready to go for tomorrow.



Also routed a space for the binding posts, just cut through half the wall thickness so the posts have enough room.



Finally, I cut a plywood ring for a little extra support behind the driver...

[dyazdani]

I've got the box assembled and sealed up. I hope to start the Bondo phase tomorrow to smooth out all the edges.

[dyazdani]

I started on the Bondo work, got one side done - have to go back and touch up a couple of areas where I went nuts with the router.

Bondo reacts funny with the flush trim bit - covers everything with what looks like shredded white cheese :E

I need to find a palm sander to borrow as well...

[ThomasW]

Don't know, never had any problems machining Bondo. I tend to use more hardener than they call for...

[dyazdani]

Don't know, never had any problems machining Bondo. I tend to use more hardener than they call for...

I didn't have any trouble - just a big mess. It was harder to clean up than sawdust because it was sort of "sticky." I was very please with how smooth it turned out - except for the areas where operator error caused some gouges ops:

[derekbannatyne]

I just started bondo-ing yesterday too. I think this stuff makes more dust than even MDF! I had to do about 6 sides where the corners join and fill in about 100 screw holes, my hands are still tired from all that sanding.

[ssabripo]

what driver are you using?

I'm sure you already mentioned it somewhere, but as you can tell, I'm dyxlexic this morning...hehehe.

[dyazdani]

I just started bondo-ing yesterday too. I think this stuff makes more dust than even MDF! I had to do about 6 sides where the corners join and fill in about 100 screw holes, my hands are still tired from all that sanding.

I don't have any screw holes, so that worked out well for me. I only had one side with any major uneven areas, I guess all the small gaps make one big one for the last piece.

I just have a few, maybe 1/32" thick places to smooth out now.

[dyazdani]

what driver are you using?

I'm sure you already mentioned it somewhere, but as you can tell, I'm dyxlexic this morning...hehehe.

None at the moment :lol: but I'm going to use a RL-p15.

[ssabripo]

ah....another RL-P!

man, HTguide is really in love with these drivers! Maybe Chasw98 and I can start to persuade others into the AV15....hehehehe.

good stuff man, keep the pics coming

[ThomasW]

Machining Bondo needs to be done with one fast swipe, otherwise it warms up and becomes tacky..

[chasw98]

ah....another RL-P!

man, HTguide is really in love with these drivers! Maybe Chasw98 and I can start to persuade others into the AV15....hehehehe.

good stuff man, keep the pics coming

Mmmmm, but I have a RL-p15 and like it a lot!

[dyazdani]

I poo-pooed some more Bondo yesterday so I gave up for the day. I guess I added a little too much hardener. It turned semi-solid before I even had a chance to spread it around.

I'll try it again tonight.

[ThomasW]

It turned semi-solid before I even had a chance to spread it around.

It's a fine line between just enough and too much. The ambient temp impacts this as well.

[dyazdani]

It's a fine line between just enough and too much. The ambient temp impacts this as well.

Yeah, I gave it one extra squeeze at the end, I figured it was too much. It was a little warmer outside as well.

After you flush trim the excess with a router, would one normally smooth things up with a sander?

[dyazdani]

I think I've got the Bondo to hardener ratio down - I basically stop at the point where I don't think I've added enough (but I really have).

I was sick today and didn't get to do much with it. I should have some pics up by the weekend.

[ThomasW]

After you flush trim the excess with a router, would one normally smooth things up with a sander?

Yep

I think I've got the Bondo to hardener ratio down - I basically stop at the point where I don't think I've added enough (but I really have).

Always helpful when one is able to effectively use psychology on one's self.... :B

[---k---]

I did my Bondo'ing in my unheated garage in 30degree weather. There was no such thing as "too much hardener".

Still worked great.

[dyazdani]

I did my Bondo'ing in my unheated garage in 30degree weather. There was no such thing as "too much hardener".

Still worked great.

It's 82 here right now, so I'm stuck with skimping on the hardener

I need to pick up some sort of sander I guess. Hopefully I can borrow one - the "boss" won't like another tool purchase.

[Red Bastard]

This design of yours looks exactly like what I've been modelling in regards to a RL-P 15" based sub.

Can you post your dimensions (external) so I can compare. Also what literage (or cubicfootage) did you arrive at??

It is sad that the RL-P's are not available in Australia and I have to order from os. The shipping is US$172!!

Chris

Yay! first post after a lot of lurking. Thanks guys/girls for all your unseen help so far. RB

[dyazdani]

My outer dimensions are 21w x 21h x 23d. I've estimated the net internal volume at 3.5 cu ft. Seems to be in line with what others have built.

[dyazdani]

I finished the last of the major Bondo work, pretty minor actually. I sanded everything smooth with my new DeWalt sander (does great BTW, thanks for the help).

I've got a couple of small places to fill with Bondo where I slipped with the roundover bit (near the ends of a couple of sides). That should take about 10 minutes and then it's cleaning and finally apply some sanding sealer.





Corner detail...

[steve nn]

Hey look at that!..it's really coming along. Nice job on the roundover.

[opt-e]

Pretty! I like. :T :clap:

[dyazdani]

Hey look at that!..it's really coming along. Nice job on the roundover.

Thanks, the roundover came out nice - except like I say for 2 small spots. I lost track of the router near the end of a couple of sides and it partially "fell off" and cut a little valley.

A dab of Bondo and some hand sanding cleared them up though, looks good as new now.

I'll apply some sanding sealer in the morning and then see what to do about painting. I get a sick feeling every time I see that $50 can of bed liner paint at WalMart. 8O

[opt-e]

Thanks, the roundover came out nice - except like I say for 2 small spots. I lost track of the router near the end of a couple of sides and it partially "fell off" and cut a little valley.

I did the exact same thing with my 'practice' Hivi B3N project. I won't be making any of those newbie mistakes on my Natalie P project



I used woodfill to fill in any mistakes. Is Bondo better/easier to work with?

[Rene D]

I take it on that close-up of the corner shot, that it's just left over dust on the top of the box?. Other wise i was going to ask what you sanded with?

On that note. what are you planning on finishing the box with?
As for the sanding sealer. put a good base coat on, Let it dry and do a quick ruff dry sand with 200 or so grit. then put a nice smooth coat on and do a very detailed wet-sand with 400-600. it makes a lot of mess. but keep a nice bucket of water around beside you with the sandpaper in it while you're sanding, keep dipping the sandpaper in the water to wash off the residue. in the end you'll get a nice glass like finish.

Rene D

[dyazdani]

I used woodfill to fill in any mistakes. Is Bondo better/easier to work with?

I like the final state of the Bondo better (durability, easy to sand, etc). Wood filler is easier to use though, no mixing or anything.

[dyazdani]

I take it on that close-up of the corner shot, that it's just left over dust on the top of the box?. Other wise i was going to ask what you sanded with?

If you ean the "stripes" they are from the Bondo that I used to smooth out the edges. I used a palm sander to sand everything smooth.

On that note. what are you planning on finishing the box with?

I haven't decided yet - I was leaning toward the bed liner paint, but that $50 price tag has me thinking about alternatives.