Scrap enclosure because of uneven sides and back panel not flush?

[omarmipi]

I am construting JohnK's (Zaph) Hi-Vi BS3 project. I have already assembled the front, sides, top, and bottom of the enclosure. I noticed that the sides on both of the enclosures were slightly higher then the bottom and top so I (stupidly) sanded down the sides with an orbital sander. Hence my problem... Because I didn't sand the sides down level the rear panel of my enclosure does not sit flush with the rest of the enclosure.

Is there anything that I can do to rescue this project? I trired leveling the sides with wood glue and mdf saw dust but that didn't work. I also filled the boxes with shorthair fiberglass so the inside is not level enough to add a brace to act as a guide for a flush bit.

Thanks in advance.

[Cal Weldon]

Can you show us a pic or two?

[omarmipi]

Originally posted by Cal Weldon
Can you show us a pic or two?

Sure can... when I get home I'll snap some pictures. At least I got the chance to practice asthetics (filling in voids, sanding, priming, sealing).

[s7horton]

unless I totally misunderstand, couldn't you run the back edges through a table saw and take off just a hair to make it straight and square again?

You'll make the enclosure smaller, but only by a very small amount..

[omarmipi]

Originally posted by s7horton
unless I totally misunderstand, couldn't you run the back edges through a table saw and take off just a hair to make it straight and square again?

I had thought of that... only problem is I do not own a table saw. I'm working with a circular saw and a cheapo home depot straight edge.

[mazurek]

Put rubber or felt feet on the bottom. Then it doesn't matter whether the rear is flush with the bottom.

[omarmipi]

Originally posted by mazurek
Put rubber or felt feet on the bottom. Then it doesn't matter whether the rear is flush with the bottom.

I'll let the pictures explain:

[rabbitz]

You need the right tools to do a good DIY job and I would suggest as good fence and a router is a must.

This is an example of a great fence and you don't have to muck about with timber and clamps as a fence which can get in the way when sawing.
http://www.carbatec.com.au/store/ind...h=60_8360_8370

There's a saw base which is not needed as you run the saw against the fence but gives you an idea how it works.
http://www.carbatec.com.au/store/ind...h=60_8360_8400

A router is a must for DIY loudspeakers.... period.

I'd suggest you saw off the back panel (using a fence as a straight guide), cut a new panel a bit oversize, glue on and then trim the overhang with a router and trimming bit.

Anything can be fixed with patience and time.

[audio-kraut]

Another option - which would decrease the box volume somewhat, could you not recut the backpanel to fit inside the box?

I also think you have to cut more slowly. I have better cuts freehand
With a straightedge and cutting slowly, make sure the base of the saw is riding along the straightedge the whole length of the base.

[Jim85IROC]

Any cutting tool when combined with a straight-edge and some clamps will work wonders for those who can't afford/justify a table saw.

When I make my rough cuts, I clamp a known-straight piece of MDF into position so that my circular saw can ride along it throughout the cut. The result is a very straight edge. I do have to admit though, that even with a cheap jig saw, you should be able to get close enough free-handed that once you screw the panels together, the MDF will fit tight or very close to it.

If you're interested in learning how to build a professional looking box with virtually no tools, let me know and I'll type it out. It's a lot of typing, so I don't want to do it for no reason.