Cabinet constructions tip, techniques, how-tos, and how-to-nots

Collapse
This topic is closed.
X
X
 
  • Time
  • Show
Clear All
new posts
  • bemis23
    Senior Member
    • May 2009
    • 157

    #1

    Cabinet constructions tip, techniques, how-tos, and how-to-nots

    Well, I've realized that building a square box is harder than it appears to be. I learned a lot building my subs the past couple weeks and I've realized that power tools can't overcome user ignorance and can't compensate for lack of experience even if you have a good plan of attack. I wanted to start a thread to try and collect and centralize a lot of the advice that is scattered throughout many of the threads on here since I didn't see one in the reference section. I know there are a few master woodworkers and some folks that may not be masters but have lots of experience with building speaker cabinets. So please share any advice, tips, tricks, warnings, cautions, possibilities, tool accessory suggestions, and anything else related to:

    Building square frames
    Building deliberately non-square frames
    Faceted baffles
    Bracing recommendations
    Helpful clamps
    Glue types/brands
    Getting a flush final product
    Hardware recommendations
    Reducing box leaks
    etc..
  • sfdoddsy
    Senior Member
    • Sep 2000
    • 496

    #2
    My best piece of advice would be to build an open baffle.

    No boxes.
    Steve's OB Journey

    Comment

    • Deward Hastings
      Senior Member
      • Dec 2006
      • 170

      #3
      Originally posted by sfdoddsy
      No boxes.
      Sounds better.

      Seriously.

      But also seriously templates and jigs are wonderful things. Just remember the Seran Wrap or waxed paper (so you don't glue them in).

      Comment

      • JoshK
        Senior Member
        • Mar 2005
        • 748

        #4
        Originally posted by bemis23
        Getting a flush final product
        etc..
        Learned that the hard way. The easiest thing to do is leave a little overhang on the last piece (say the baffle) and then true it up with a flush trim bit on your router. The back can be done the same way and the top/bottom can be done on the two joints each. That leaves only the sides that need to really be precisely the same size.

        For the sides I set the fence on the table saw to what it should be on each cut and pass them both through, one after the other without moving the fence. You have to ensure the fence is really square to your blade first, which is always a good thing anyway (to check).

        Comment

        • David_D
          Senior Member
          • Feb 2008
          • 197

          #5
          The single best piece of advise I could give is to plan one's cuts so, alike pieces can be cut without moving the saw fence.
          -David

          As we try and consider
          We receive all we venture to give

          Comment

          • Bear
            Super Senior Member
            • Dec 2008
            • 1044

            #6
            Originally posted by David_D
            pieces can be cut without moving the saw fence.
            Amen, hallelujah!! This is tip #1 after the ubiquitous "measure twice, cut once".
            Welcome to Rivendell, Mr. Anderson.

            Comment

            • soundemon
              Senior Member
              • May 2009
              • 136

              #7
              When assembling, jig and dry-fit like crazy before applying glue. plan where your clamps are going to go, how many to use etc. When the glue is down, the pressure is on.

              I like to jig whenever I can - set up a glue so the peice can't shift. (as invariably happens when clamping a glue joint) In this pic you can see 90 degree jigs I
              -clamp to the upright
              -position the piece on the flat board
              -clamp to the flat board
              - remove clamps from the upright. After putting glue down I'll place the piece down and clamp it to the jigs.

              Also not pictured (I'd removed them) I clamp 2 boards to either side of the flat board, so the upright cannot shift side to side.


              Click image for larger version

Name:	DAC-1001.webp
Views:	137
Size:	21.5 KB
ID:	947996
              Last edited by theSven; 13 August 2023, 11:24 Sunday. Reason: Update image location
              DIY - once you start down that (dark) path, forever will it dominate your destiny!

              Comment

              • Bill Schneider
                Senior Member
                • Sep 2007
                • 158

                #8
                I've become a big fan of using biscuits to align parts for gluing. Cutting biscit slots freehand was inaccurate because of the way the cutter's fence had only 3/4" to ride on for squaring a face cut.

                I made a biscuit cutting jig that takes all the work out of cutting the slots, and ensures a square slot.

                Here's a couple photos of the biscuit cutting jig...

                Click image for larger version

Name:	biscuit_jtr_jig1.jpg
Views:	89
Size:	86.1 KB
ID:	947997

                Click image for larger version

Name:	biscuitjig1txt_sml.jpg
Views:	75
Size:	95.8 KB
ID:	947998

                ..and here are a couple cabinets being assembled using biscuits. I like how the cabinet sides themselves become a jig for assembling the opposite side and verticals.

                Click image for larger version

Name:	zdt35_biscuit_joints-021Tsml.jpg
Views:	78
Size:	99.1 KB
ID:	947999
                Last edited by theSven; 13 August 2023, 11:26 Sunday. Reason: Update image lcoation
                My audio projects:
                https://www.afterness.com/audio

                Comment

                • Bill Schneider
                  Senior Member
                  • Sep 2007
                  • 158

                  #9
                  When crosscutting long pieces, I've made an adjustable stop that I bolt to the side of the table saw. Coarse adjustments are made by sliding a shoe along a board, and fine adjustments are made using a 3/8-16 carriage bolt.

                  I used some angle iron under the center of the board to support it sufficiently without sag.

                  Click image for larger version

Name:	table_saw_crosscut_stop-1.jpg
Views:	75
Size:	80.0 KB
ID:	948000

                  Click image for larger version

Name:	table_saw_crosscut_stop-2.jpg
Views:	74
Size:	56.9 KB
ID:	948001

                  Click image for larger version

Name:	table_saw_crosscut_stop-5b.jpg
Views:	80
Size:	109.7 KB
ID:	948002

                  In the last picture, you can see that the inset shows that I met the 40.25 inch length specified for a ZDT3.5 tower. Worked like a charm on all the cuts.
                  Last edited by theSven; 13 August 2023, 11:27 Sunday. Reason: Update image location
                  My audio projects:
                  https://www.afterness.com/audio

                  Comment

                  • Bill Schneider
                    Senior Member
                    • Sep 2007
                    • 158

                    #10
                    When I purchase MDF at Lowe's, I have them make a couple of cuts so that a 4x8 sheet will fit into my Toyota Matrix. When asking for the cut, I always hand the worker this diagram to ensure that it will give me the best size to work with, and it helps to ensure squareness of the parts by making the vertical cut first. And there's no confusion.

                    Click image for larger version

Name:	mdf-cut-from-lowes.gif
Views:	76
Size:	6.6 KB
ID:	948003

                    Then I take these somewhat large pieces, and use sawhorses, a circular saw, and a quality straightedge to cut it down further. I use a combination square to set the distance of cut so that it's very parallel to the opposite side.

                    Click image for larger version

Name:	circular-saw-cuts.gif
Views:	75
Size:	32.8 KB
ID:	948004

                    After clamping both ends of the straightedge with the square setting the proper distance, the square gets clamped at the center of the rule during the cut to minimize straightedge flexing in the center.
                    Last edited by theSven; 13 August 2023, 11:28 Sunday. Reason: Update image location
                    My audio projects:
                    https://www.afterness.com/audio

                    Comment

                    • cobbpa
                      Senior Member
                      • Apr 2005
                      • 456

                      #11
                      Agreed with others--move the saw blade as little as possible. Leaving a little extra to trim off isn't a bad idea either.

                      This weekend my cousin and I "took it to the next level," for us...we made miter cuts on the interior edges, then used biscuits to ensure alignment. We came up with some great looking angles

                      Comment

                      • JoshK
                        Senior Member
                        • Mar 2005
                        • 748

                        #12
                        Glad to see others enjoy using biscuit jointers. I have to say, I love mine! Makes life much easier when gluing up.

                        Comment

                        • cobbpa
                          Senior Member
                          • Apr 2005
                          • 456

                          #13
                          To quickly answer a couple of the other questions:
                          --Use basic wood glue; Tite Bond works perfectly
                          --To help have a sealed/tight box, go over the interior seams with silicon latex caulk before closing it up
                          --Hand-tightened (trigger style?) clamps are good and I certainly use them a lot, but they usually can't place the pressure that traditional pipe clamps / any screw-tightened clamp can
                          --To have a flush final product, either clamp carefully & use guides to have things flush before they dry, or go over edges with a flush-trim bit in the router after
                          --Square guides like Soundemon posted pictures of are great. I have cut these out of scrap on the table saw before & used with good luck.

                          Those are my quick answers; I'm sure someone with more experience can correct me on most of them!

                          Comment

                          • Undefinition
                            Senior Member
                            • Dec 2006
                            • 577

                            #14
                            I went from using screw 'n glue, to biscuits, now to a brad nailer. There was like an exponential decrease in time required to build the enclosures. I still use jigs to make sure things are square as I put the nails in. But the beauty is that brad nails eliminate the need for clamping; once a side has enough nails in it, it's enough force to hold the panels together as the glue dries. A dab of wood putty or Bondo will fill the divot created by the brad's head.

                            Of course, it's not always about working fast. If I was a more patient woodworker (that is, more of a "skilled builder" instead of a "designer") I think I'd rather take my time and use biscuits.

                            Images not available
                            Last edited by theSven; 13 August 2023, 11:30 Sunday. Reason: Remove broken image links
                            Isn't it about time we started answering rhetorical questions?
                            Paul Carmody's DIY Speaker Site

                            Comment

                            • Rolex
                              Senior Member
                              • Mar 2005
                              • 386

                              #15
                              I use the aluminum angles that soundemon mentions. My preferred method of construcion requires three things. Glue, screws, and pin nailer. I apply glue to both sides, align till I'm happy, pin nail so it doesn't move, then screw it together. Biscuits are fine, and sometimes I use them for the front baffle. I don't find I need them for alignment though. I can get as perfect as I care for with clamps and pin nailer. I'm fortunate enough to have some nice toys in my shop including:

                              Click image for larger version

Name:	2.webp
Views:	132
Size:	12.7 KB
ID:	948005

                              Delta unisaw with excaliber sliding table. Accurate panel cuts become very strightforward and repeatable with this setup. I find that I don't need to trim baffle edges with the router to make them flush.

                              One trick I used to use before the pin nailer was to dry clamp everything and drill a couple screw holes before the glue (I like the countersink bits seen below). That was my alignment since things get slippery once th glue is on. Then, apply glue, and use the screws to assist with alignment.

                              Image not available
                              Last edited by theSven; 13 August 2023, 11:31 Sunday. Reason: Remove broken image link

                              Comment

                              • Hank
                                Super Senior Member
                                • Jul 2002
                                • 1343

                                #16
                                My 30+ years has taught me (long ago) to not use the expense and time-wasting screw method. Accurately cut right angle panels will butt-join fine and sufficient glue will ensure a strong joint. Screws, nails and biscuits are not needed. When building a tower cabinet, because of its weight an unweildy-ness, I use my 18 guage brad nailer to hold panels in place while I apply clamps. Lots of great advice in this thread, now jump in and make some sawdust.

                                Comment

                                • Rolex
                                  Senior Member
                                  • Mar 2005
                                  • 386

                                  #17
                                  Originally posted by Hank
                                  My 30+ years has taught me (long ago) to not use the expense and time-wasting screw method. Accurately cut right angle panels will butt-join fine and sufficient glue will ensure a strong joint. Screws, nails and biscuits are not needed. When building a tower cabinet, because of its weight an unweildy-ness, I use my 18 guage brad nailer to hold panels in place while I apply clamps. Lots of great advice in this thread, now jump in and make some sawdust.
                                  Interesting that you find screws time wasting. I use screws to hold the cabinets together while the glue is drying. I have zero clamp time when assembling a cabinet. Speeds the process up immensly if you ask me.

                                  Comment

                                  • Bill Schneider
                                    Senior Member
                                    • Sep 2007
                                    • 158

                                    #18
                                    Here's another thing I learned the hard way - squares are sometimes not square. In particular, one-piece framing squares seem to have the most problem. Combination squares with sliding scales are usually better made, but more expensive.

                                    If your square isn't square, then your saw alignment, measurements, etc. can all be off.

                                    Here's a tip that's obvious once you've seen it...

                                    Click image for larger version

Name:	square-checking.gif
Views:	72
Size:	13.2 KB
ID:	948006

                                    Place your square on an edge and scribe a line. Flip it over and scribe again. If the two lines converge or diverge, your square isn't square.

                                    I have both a 12" Starrett square (expensive, but very high quality) and a longer 16" square from Lowe's for when I need a little extra reach. The Starrett, as you might expect, gets handled gently. The other one is my beat-about, and I can check it against the Starrett if I suspect damage.
                                    Last edited by theSven; 13 August 2023, 11:32 Sunday. Reason: Update image location
                                    My audio projects:
                                    https://www.afterness.com/audio

                                    Comment

                                    • krips
                                      Senior Member
                                      • Sep 2007
                                      • 264

                                      #19
                                      Originally posted by Rolex
                                      Interesting that you find screws time wasting. I use screws to hold the cabinets together while the glue is drying. I have zero clamp time when assembling a cabinet. Speeds the process up immensly if you ask me.
                                      Depends on the material, doesn't it? Trying to screw MDF, even with pre-drilling, is pretty much impossible in my experience. Works well with ply thoughl
                                      Sharp LC-42D64U
                                      TriTrix MTM (Sealed)

                                      Comment

                                      • Rolex
                                        Senior Member
                                        • Mar 2005
                                        • 386

                                        #20
                                        Originally posted by krips
                                        Depends on the material, doesn't it? Trying to screw MDF, even with pre-drilling, is pretty much impossible in my experience. Works well with ply thoughl
                                        Maybe. Though I have had tremendous success screwing into MDF with pre-drilling. Coarse thread screws about 1 5/8" long. You can't stess the joint until after the glue is dry, but it holds tight enough to let the glue do its job and move on to the next piece without clamps.

                                        With proper care (avoiding end splitting) and the right application, screws work well for me.

                                        Comment

                                        • collo
                                          Member
                                          • Nov 2005
                                          • 67

                                          #21
                                          Is self-promotion allowed if it's relevent?
                                          Some tips on glues / sawboards / routing / box building walk-thru / grilles here
                                          Ports rule ...

                                          Comment

                                          • Brian Walter
                                            Senior Member
                                            • Sep 2005
                                            • 318

                                            #22
                                            So far I have to agree with almost all of the comments and suggestions. I say almost all because I haven't necessarily tried all of the suggestions, so I can't say for certain. One point I would like to stress is Bill's point about not all squares being square, especially Carpenter squares. Also, one of the problems with using Carpenter squares is that it can be easy to not have the square tight against the wood, resulting in errors. I have seen a trick where you screw a couple pieces of wood (or a single piece with a slot in it) to either side of one leg of the square, essentially making a "T" square out of it. It might take a little work getting the wood set so the square is a true 90 degrees, but once set it should make using the square much easier and improve the accuracy of your work.

                                            Also, if you are using a table saw it pays big time to align everything correctly. This means setting the miter gauge parallel to the blade, the rip fence parallel to the blade and making sure your miter gauge or sleds if you use them are set to truly cut at 90 degree or whatever angle you want. If you don't do this you will be constantly fighting with your saw trying to get accurate cuts. If your saw is miss-aligned, you might be better off simply using a square, sawboard and circular saw for your cuts and a router to trim things flush.

                                            Comment

                                            • soundemon
                                              Senior Member
                                              • May 2009
                                              • 136

                                              #23
                                              Originally posted by Brian Walter

                                              Also, if you are using a table saw it pays big time to align everything correctly. This means setting the miter gauge parallel to the blade, the rip fence parallel to the blade and making sure your miter gauge or sleds if you use them are set to truly cut at 90 degree or whatever angle you want. If you don't do this you will be constantly fighting with your saw trying to get accurate cuts. If your saw is miss-aligned, you might be better off simply using a square, sawboard and circular saw for your cuts and a router to trim things flush.
                                              +1
                                              I spent about 4 hours setting up my table saw when I first got it to make sure everything was sqyare and true. time well spent!
                                              DIY - once you start down that (dark) path, forever will it dominate your destiny!

                                              Comment

                                              • Hank
                                                Super Senior Member
                                                • Jul 2002
                                                • 1343

                                                #24
                                                screws work well for me
                                                Huge waste of time for me, because when finish time comes, you've got to fill the screw head depressions, sand perfectly level, and then hope the filler doesn't expand and contract at a different rate than the MDF.
                                                But, to each his own - the objective is to build good cabinets. :-)

                                                Comment

                                                • WayneW
                                                  Junior Member
                                                  • Jul 2009
                                                  • 11

                                                  #25
                                                  I like to use clamps rather than screws. That way, I don't have to fill or putty any of the holes, also, screws don't really give good even pressure like clamps do. I go an extra step and use clamp cauls as well, to spread the load out and get consistant pressure. Also, the tip about over-sizing and flush trimming is a great tip. Finding a square that is square can be a challenge. I use a Sheffield square and it is the first one I have found that stays square throughout the year.

                                                  Comment

                                                  • aduljr
                                                    Junior Member
                                                    • Nov 2007
                                                    • 16

                                                    #26
                                                    I recently started to use a pocket hole jig I got from kreg. That with a clamping guide to keep things square really helps will speed of assembly.

                                                    counter sinking bracings and parts into the sidewalls.

                                                    I also measure, measure, measure. I try to plan my cuts to be slight oversize a little.

                                                    I then take pieces that are the same cut size and run them through the table saw for the finally cut. I get real consistent sizes this way.

                                                    I make sure my table saw is square and that the fence is no more then 1/32 of an inch off or less.

                                                    Comment

                                                    • Doug Fraser
                                                      Member
                                                      • Apr 2004
                                                      • 62

                                                      #27
                                                      The one thing that has really helped me is to plan the cuts so that all of the cuts of a given size are done at once. The problem is that I find it almost impossible to set the fence to exactly the same measurement again if I have to go back and reset the fence.

                                                      So if the speakers are to be say 9" wide then I cut all of the 9" wide pieces (tops, bottoms, sides, baffles - whatever) that should be 9" wide. This way I do not have to readjust the fence on the table saw and all the 9" wide pieces are well - the same width.

                                                      For me the next important item is the biscuit joiner. This tool allows very accurate alignment of the various pieces. When clamped, the box almost squares itself. It is important to dry assemble the box first to make sure everything fits. If one uses the outside as the reference edge then and inaccuracies due to stock thickness are eliminated. Bill Schneider has posted some very good photo's (above) of biscuits being used. His biscuit table is a excellent idea. I use a biscuit joiner without a table and get great results.

                                                      In order to get square cuts from sheet goods I use the Jessem sliding table attachment.

                                                      Woodworking Tools, Woodworker, Router, Router Table, Dowelling Jig, Loose Tenon Mortising Jig, Stock Guides, Table Saw Accessories, Router Accessories, Joinery, Joinery Tools, Production, CNC, Metal, Wood, Miter Gauge, Fence.


                                                      Click image for larger version

Name:	Sliding Table 2.jpg
Views:	2961
Size:	55.6 KB
ID:	853769

                                                      One has to remove the left side table wing on your saw. At first I was apprehensive about not having the wing but the convenience of the sliding table far outweighs not having the wing.

                                                      Regards,
                                                      Doug
                                                      Last edited by theSven; 13 August 2023, 11:24 Sunday. Reason: Update image location

                                                      Comment

                                                      • evilskillit
                                                        Senior Member
                                                        • Oct 2008
                                                        • 468

                                                        #28
                                                        Screws & MDF

                                                        I find that after having built a few projects I prefer not to use screws. It makes the initial assembly take a bit longer but if you want a good finish it saves a fair amount of time and work in the back end taking care of the divots the counter-sunk screw heads leave behind. Plus I guess I'm just a bit obsessive and consider it to be a matter of principal. The screws don't do anything once the glue is dry anyways so whats the point?

                                                        However, if you do want to use screws with MDF here is what I have leared. Get the right screws, good coarse wood screws that are lacking thread on the top 3/4 inch. That will keep the threads from pushing the 2 pieces of wood apart instead of using the head to pull the wood together.

                                                        Also if you want to go the extra mile they make screws specifically for MDF that have the qualities I described, plus extra corase threads that are actually serrated for extra bite, here is an example.

                                                        http://www.drillspot.com/products/39...0453_Mdf_Screw

                                                        Comment

                                                        • Robert F.
                                                          Member
                                                          • Apr 2007
                                                          • 34

                                                          #29
                                                          Tools
                                                          One of the most used tools I have is the Black & Decker Workmate. It holds the parts as I use other tools on those parts

                                                          Usefull for speakers or building an astronomical telescope, or even a trebuchet.

                                                          Luck with your project and keep your eye on the blade and don't cut off your fingers!

                                                          Comment

                                                          • bemis23
                                                            Senior Member
                                                            • May 2009
                                                            • 157

                                                            #30
                                                            Bump for more tips. I know there's a lot more knowledge out there!!

                                                            Comment

                                                            • NoDestiny
                                                              Member
                                                              • Jan 2009
                                                              • 97

                                                              #31
                                                              Good thread, some things I knew, some things I didn't.

                                                              My only thing that I can throw in there is the order in which you assemble. Always try to make it so the last piece goes on "top" of everything, that way glue always goes on properly. For instance, I usually do an enclosure with the front/back as the biggest pieces (full width and height), the top and bottom the full width, but the depth is 2x minus the wood thickness, then the sides are 2x minus wood thickness in both directions of the maximum of the box. Then, I generally do bottom to from, sides, top, then the back. Never have to "press" anything in, glue always goes on best. If you try to put the sides in last, good luck getting glue in there properly!

                                                              Comment

                                                              • Licinius
                                                                Member
                                                                • Sep 2006
                                                                • 70

                                                                #32
                                                                Get a shop vac, almost every power tool you can buy can be rigged up to a vac without almost no problems, table saws, routers, jigsaws, sanders... And everything around you will rejoice.

                                                                Comment

                                                                • Bill Schneider
                                                                  Senior Member
                                                                  • Sep 2007
                                                                  • 158

                                                                  #33
                                                                  And if you have a shop vac, you'll eventually want a Dust Deputy to keep the filter from becoming clogged with MDF dust.

                                                                  Click image for larger version

Name:	Plas-DD-Ani-20ms.gif
Views:	72
Size:	321.2 KB
ID:	948007
                                                                  Last edited by theSven; 13 August 2023, 11:32 Sunday. Reason: Update image location
                                                                  My audio projects:
                                                                  https://www.afterness.com/audio

                                                                  Comment

                                                                  • LHD
                                                                    Junior Member
                                                                    • Oct 2008
                                                                    • 28

                                                                    #34
                                                                    Quality clamps are a must. Quality doesnt mean expensive but usually the more expensive ones are pretty nice. The only things I'm willing to buy in a harbor freight are clamps and compressor fittings. Both generally do the job pretty well but if you get a lemon can be exchanged for a good one.

                                                                    Unless you're working with exactly enough material to do a job cut your sheet goods between 1/8" and 1/2" oversize. Then you can either fence cut all the peices of the same dimension at the same time or flush trim it with a router. Plus its much easier to get a nice edge when you're pushing a piece of material that's only 1/2" bigger than your finished product than a full 4x8 sheet.

                                                                    That being said..

                                                                    Dont cut full sheets on a table saw unless you have to. Sawhorses, a guide and a circular saw (or plunge saw kit) take a lot of the frustration out of trimming large sheets down to the sizes you need.

                                                                    Make sure you account for kerf in your measurement. Are you cutting to the side of the line or cutting the line out? When you set up your measurement did you just read the number on the fence or measure between the inside edge of the blade and the fence?

                                                                    Jig what you can jig anytime you can jig it. Jig.

                                                                    I have a cnc router on the way that will hopefully take a lot of the minutia out of this but it alone will not make quality boxes. It still takes lots of planning and preparation. Garbage in, garbage out. Very precise garbage but garbage none the less.

                                                                    Comment

                                                                    • mwmkravchenko
                                                                      Junior Member
                                                                      • Oct 2009
                                                                      • 1

                                                                      #35
                                                                      Hi guys.

                                                                      I'm new to the forum but definitely not new to Cabinet Making. 25 years worth. And lots of speaker boxes. So my two cents is as follows.

                                                                      A brad nailer or screw is used to hold parts together until the glue sets. It is the glue joint that means the most. Granted a screw has some mechanical holding power. But consider that it is only in a small location compared to a proper fitting glued joint. Brads I use regularly to hold things together until the glue sets.

                                                                      Types of glue are also important. For boxes that are not directly painted to look beautiful I use PL Premium polyurethane construction adhesive. It comes in a caulking tube. It expands as it sets so it seals up any voids that you may have. It must be nailed up or screwed or something because it will expand and take apart the box if it is not held together.

                                                                      Some other tips.

                                                                      When using MDF and wanting to get a box that takes a nice paint job use mitered corners. The surface of MDF and the inside have different densities that take paint and absorb and release moisture at unequal rates.

                                                                      Finishing of painted boxes that are supposed to look like a million bucks should have their interiors coated almost as well as their exteriors. It keeps the moisture transfer down to a minimum. The uneven transfer of moisture from inside the box to outside the box is the source of many problems when using MDF.

                                                                      One other tip while I'm thinking about MDF and mitered joints.

                                                                      Images not available

                                                                      Beats the heck out of clamps and is dirt cheap. Good quality packing tape and masking tape can be used many times where you might use clamps.

                                                                      Mark
                                                                      Last edited by theSven; 13 August 2023, 11:33 Sunday. Reason: Remove broken image links
                                                                      Some peoples minds are like concrete all mixed up and permanently set.

                                                                      Comment

                                                                      • NoDestiny
                                                                        Member
                                                                        • Jan 2009
                                                                        • 97

                                                                        #36
                                                                        Originally posted by soundemon
                                                                        When assembling, jig and dry-fit like crazy before applying glue. plan where your clamps are going to go, how many to use etc. When the glue is down, the pressure is on.

                                                                        I like to jig whenever I can - set up a glue so the peice can't shift. (as invariably happens when clamping a glue joint) In this pic you can see 90 degree jigs I
                                                                        -clamp to the upright
                                                                        -position the piece on the flat board
                                                                        -clamp to the flat board
                                                                        - remove clamps from the upright. After putting glue down I'll place the piece down and clamp it to the jigs.

                                                                        Also not pictured (I'd removed them) I clamp 2 boards to either side of the flat board, so the upright cannot shift side to side.


                                                                        Click image for larger version  Name:	DAC-1001.webp Views:	0 Size:	21.5 KB ID:	947996
                                                                        I read this and decided to give it a try. My boxes are coming out straighter and seem much easier in the long run, though it does obviously take a little longer... but when doesn't quality?
                                                                        Last edited by theSven; 13 August 2023, 11:33 Sunday. Reason: Update quote

                                                                        Comment

                                                                        • Brian Kingsbury
                                                                          Member
                                                                          • Sep 2009
                                                                          • 44

                                                                          #37
                                                                          I bought four 3" 90deg corner clamps from my local hardware store for ~$8 each and they really simplify gluing. They're not a perfect 90deg by themselves but they do keep things clean and steady while I get everything lined up and clamped with my other tools.
                                                                          ;x( We're not worthy! ;x(

                                                                          Comment

                                                                          • David LR
                                                                            Junior Member
                                                                            • Jul 2009
                                                                            • 7

                                                                            #38
                                                                            Removable Baffles

                                                                            Hi-

                                                                            Seems like a very appropriate thread to ask these questions. I am making a pair of the Zaph ZMV5's for my daughter. Would like to go the removable baffle route & could use some tips on baffle construction.

                                                                            The baffle is constructed of two thicknesses of 3/4 MDF. My table saw & skill set require that I make them slightly oversize & then use the to flush trim . As far as I can tell, I"ll need some way to temporarily but firmly attach the baffle to the box in order to properly do the flush trim. Any ideas on attachment methods ??

                                                                            Thought of using clamps but couldn't clamp all four sides at once as they woud get in they way of the router. Probably would clamp the long sides, trim both ends, then clamp the ends, remove original clamps & trim the sides. Seems clumsy though, I can see the clamps still getting in the way, small box-big router.

                                                                            Also thought of using double sided sticky tape. Would this hold the baffle firmly enough to the box to allow routing ? Thanks for any ideas or suggestions.

                                                                            In addition, there is the matter of rabbeting both the cabinet & baffle edges to allow an inset baffle. So, how do you all do this ?? Seems to me you could rabbet the appropriate cabinet edges before assembly. Or, I suppose the rabbeting could be done after box assembly but I'd think it might be difficult to balance the router on an edge only 3/4 " wide.

                                                                            Could the rabbeting be done on the assembled box if a router table was used ?

                                                                            Ah, one more question. Since the MDF is 3/4" thick, I assume the rabbet dimensions would be 3/8" both ways, no ?? I have seen where a rabbet will be 1/2" deep but only 3/8" wide. Would allow for thicker gasket material I suppose. Any thoughts here ?


                                                                            Just a few questions & thoughts. Hope I haven't been to rambling. Thanks again for your help & advice.


                                                                            Dave

                                                                            Comment

                                                                            • Bill Schneider
                                                                              Senior Member
                                                                              • Sep 2007
                                                                              • 158

                                                                              #39
                                                                              Why don't you work out the baffle mounting method, attach it with the screws you plan to use, THEN route flush? That way you don't have to worry about temporary means like tape or any possible shifting.

                                                                              EDIT: Oh, wait... the rabbet on the front baffle requires a flush fit BEFORE you can do the rabbet. (Slaps forehead!) I see the issue. Never mind the above suggestion for your situation.

                                                                              FWIW, on my own ZMV5 build, I didn't rabbet the front baffle, but added a slightly inset frame made from pine. The inset allowed for compression of gasket material but still permitted the baffle to lie flush with the cabinet.

                                                                              Click image for larger version

Name:	zmv5_seal_frame.jpg
Views:	71
Size:	59.5 KB
ID:	948008

                                                                              The odd cutouts on the inner frame were made for clearance of driver frames, etc.
                                                                              Last edited by theSven; 13 August 2023, 11:34 Sunday. Reason: Update image location
                                                                              My audio projects:
                                                                              https://www.afterness.com/audio

                                                                              Comment

                                                                              • Bill Schneider
                                                                                Senior Member
                                                                                • Sep 2007
                                                                                • 158

                                                                                #40
                                                                                I'll follow up on your question about routing the rabbet on an assembled cabinet - yes, you want a router table. Tipping of the router WILL happen if you don't use a router table (or devise some complex support for the router base).

                                                                                There's another factor to consider though - when you route an assembled cabinet, you will end up with round corners in the rabbet.

                                                                                Click image for larger version

Name:	os_enclosure_routing-025tsml.jpg
Views:	73
Size:	74.3 KB
ID:	948009

                                                                                For a inset baffle, you could use a chisel to square up the rabbet corners, but I haven't done that.
                                                                                Last edited by theSven; 13 August 2023, 11:35 Sunday. Reason: Update image location
                                                                                My audio projects:
                                                                                https://www.afterness.com/audio

                                                                                Comment

                                                                                • David LR
                                                                                  Junior Member
                                                                                  • Jul 2009
                                                                                  • 7

                                                                                  #41
                                                                                  Removable Baffles

                                                                                  Bill-

                                                                                  Thanks very much for responding.

                                                                                  "EDIT: Oh, wait... the rabbet on the front baffle requires a flush fit BEFORE you can do the rabbet. (Slaps forehead!) I see the issue. Never mind the above suggestion for your situation."

                                                                                  Funny. Glad you see my issue. Take it easy on the forehead though. Don't want to damage those woodworking & speaker building gray cells ! You are clearly one of the top-notch woodworkers on the forums.

                                                                                  What would be the problem with rabbeting the pieces before assembly ? I guess you would have to be super acccurate in your glue-up to make all the rabbeted edges line up.

                                                                                  Some many people use this kind of baffle, I just thought there was some common methodolgy I could make use of.

                                                                                  Your idea of the inset frame would work I think. I assume the additional internal volume taken by the frame is negligible & would not impact the required volume per Zaph's design.

                                                                                  Comment

                                                                                  • Bill Schneider
                                                                                    Senior Member
                                                                                    • Sep 2007
                                                                                    • 158

                                                                                    #42
                                                                                    Originally posted by David LR

                                                                                    What would be the problem with rabbeting the pieces before assembly ? I guess you would have to be super acccurate in your glue-up to make all the rabbeted edges line up.
                                                                                    That works great IF you plan to cut miters for the joints. Here's an illustration that shows why...

                                                                                    Click image for larger version

Name:	rabbetting-cabinets.gif
Views:	70
Size:	18.7 KB
ID:	948010

                                                                                    In example A showing miters (in gray), you can see that you get a nice right-angle recess for a baffle to nest into. The rabbet is cut into the entire length of the edge, but doesn't leave any gaps.

                                                                                    In example B, cutting a rabbet for the full length of the piece would leave a gap in a butt-joint. Not good.

                                                                                    In example C, using a typical 1-1/2" diameter rabbeting bit with interchangeable bearings, you could try to stop the cut as short as possible, but still you run into the problem of a gap.

                                                                                    I didn't show a potential example D, which is where you use a small-diameter bit, a fence for the router table, and cut LESS than half-way through the material i.e., you cut a rabbet less than 3/8" deep on 3/4" MDF. That could work, but you'll have to sketch it out to scale to see the possibilities.

                                                                                    Keep in mind also that pre-rabbeted boxes must be assembled very square to accept a rectangular mating pieces.

                                                                                    Do you have your double-thickness baffles glued up yet? If not, consider making the inside piece first and fitting it into the rabbet you make, then glue on an oversize outer baffle. Then mark and cut driver openings, and flush trim the outer part.

                                                                                    Doing it this way means you could assemble cabs, route the rabbet in the cabinet face, then cut and trim the inner baffle piece to fit. I managed to cut round corners on the backs of my Overnight Sensations very easily using a band saw for a rough cut, then sanding to fit.

                                                                                    Click image for larger version

Name:	os_back_work-030tsml.jpg
Views:	71
Size:	92.6 KB
ID:	948011

                                                                                    Because the part of the baffle in your build will be inside and not visible, extreme care won't be required.
                                                                                    Last edited by theSven; 13 August 2023, 11:36 Sunday. Reason: Update image location
                                                                                    My audio projects:
                                                                                    https://www.afterness.com/audio

                                                                                    Comment

                                                                                    • David LR
                                                                                      Junior Member
                                                                                      • Jul 2009
                                                                                      • 7

                                                                                      #43
                                                                                      I see what you are saying. The "pre-rabbited" edges would have the rabbet going all the way through to the front of the speaker, unless you stopped short, as you say

                                                                                      And yes, I have already glued up the double-thick baffles.

                                                                                      Well, these are for my daughter, she is never going to need to have removable baffles. I wanted to do it just do do it, to increase my skills, etc. But, maybe not this project. Need to have them done by Thanksgiving. I'll probably just glue baffles on, do the flush trim & continue. Much simpler.

                                                                                      By the way, Bill, if I remember right, you got started in this hobby by building a set of the North Creek Echo's. How would you compare the sound of the Echo's vs the ZMV5's ?? I ask this because I previously constructed the North Creek Ikara Ikemos.

                                                                                      Was always a little let down by the sound, particularly after so much work on such a small cabinet. Not bad, mind you, they can sound very good with proper material. Just not what I was expecting after reading such glowing reviews. I guess I shouldn't base my expectations on "testimonials" posted on the providers website.

                                                                                      Comment

                                                                                      • Bill Schneider
                                                                                        Senior Member
                                                                                        • Sep 2007
                                                                                        • 158

                                                                                        #44
                                                                                        To keep the thread on topic, I'll answer the question concerning the differences between the two speakers in a private message to you.


                                                                                        EDIT: David - check your private messages on the board here. You can see waiting messages in the little Welcome box on the upper right.
                                                                                        Last edited by Bill Schneider; 04 November 2009, 15:37 Wednesday.
                                                                                        My audio projects:
                                                                                        https://www.afterness.com/audio

                                                                                        Comment

                                                                                        • Brian Walter
                                                                                          Senior Member
                                                                                          • Sep 2005
                                                                                          • 318

                                                                                          #45
                                                                                          Originally posted by David LR
                                                                                          Bill-

                                                                                          What would be the problem with rabbeting the pieces before assembly ? I guess you would have to be super acccurate in your glue-up to make all the rabbeted edges line up.
                                                                                          You certainly can rabbet the pieces before assembly, but as Bill pointed out there are some problems associated with that technique. I find the best bet is to do the rabbets' on the router table and route the top and bottom completely from end to end and use stopped rabbets on the sides, stopping the rabbet just short of the rabbet on the top and bottom. Then, after assembly, use a chisel to square up the corners. They make a special corner chisel for doing that http://www.rockler.com/product.cfm?page=19422, but I don't have any experience using one so I can't comment on how well they work.

                                                                                          I typically don't use a rabbeting bit for making rabbets, I simply use a 1/2" or 3/4" straight cut bit and set my fence and depth of cut to whatever size rabbet I want. A good woodworker learns to use hand tools, i.e. chisels, planes, etc. along with the power tools. It's amazing how often I grab for a chisel or plane to clean up something or simply do something my power tools don't do.

                                                                                          Brian Walter

                                                                                          Comment

                                                                                          Related Topics

                                                                                          Collapse

                                                                                          • syzygylock
                                                                                            New at building speaker box..Have a question
                                                                                            by syzygylock
                                                                                            Hi all, I'm looking to make DIY speakers and I've looked at a lot of DIY speakers diagram and stuffs. But one thing that I'm not clear on is the internal speaker's box construction. The diagram didn't specify much or any at all, yet from looking at many other DIY projects and cabinets, I see the constructions...
                                                                                            16 September 2007, 04:01 Sunday
                                                                                          • brendon
                                                                                            Advice sought on building speaker stands
                                                                                            by brendon
                                                                                            Hi All ,I am currently looking at buying some bookshelf style speakers as fronts for a home theater sytem and I am thinking about about building the stands my self as budget is limited.I would love to hear your thoughts on best construction techniques and materials.I am reasonably handy and have access...
                                                                                            15 September 2004, 06:15 Wednesday
                                                                                          • thadman
                                                                                            Numerical Solving Techniques for Optimum Crossover Design
                                                                                            by thadman
                                                                                            I've been contemplating an optimum method to achieve synergy between drivers in a loudspeaker. We obviously need crossovers to transition between drivers, but what techniques can we use to optimize the crossover filter so that radiated energy is as uniform as possible throughout the crossover region...
                                                                                            20 May 2009, 16:37 Wednesday
                                                                                          • thasqgotme
                                                                                            Speaker finishes/techniques that aren't veneer?
                                                                                            by thasqgotme
                                                                                            I am about to embark on my first DIY home speaker build. I am going to be building the Shticks (as long as my mind doesn't change for the billionth time by tomorrow ) .

                                                                                            Anyway, I have never done veneer before, or used a router for anything but doors and door jambs. I was wondering...
                                                                                            08 January 2009, 02:30 Thursday
                                                                                          • DIY_newbie
                                                                                            Both h-frames completed
                                                                                            by DIY_newbie
                                                                                            As promised..

                                                                                            2 Frames glued and screwed together. The left one has speaker spikes installed, I'm wating on a set for the right one. The mid/tweeter panels are still mocked up from cardboard, I'll start working on the MDF panels this week.

                                                                                            I've purchased some really nice Mohagony...
                                                                                            16 September 2005, 23:25 Friday
                                                                                          • Loading...
                                                                                          • No more items.
                                                                                          Working...
                                                                                            Searching...Please wait.
                                                                                            An unexpected error was returned: 'Your submission could not be processed because you have logged in since the previous page was loaded.

                                                                                            Please push the back button and reload the previous window.'
                                                                                            An unexpected error was returned: 'Your submission could not be processed because the token has expired.

                                                                                            Please push the back button and reload the previous window.'
                                                                                            An internal error has occurred and the module cannot be displayed.
                                                                                            There are no results that meet this criteria.
                                                                                            Search Result for "|||"