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Old 18th October 2011, 02:40 AM   #991
jdkJake is offline jdkJake  United States
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I am going to give the edge banding a go. I have a friend who builds furniture grade cabinets and he has not experienced the issues you have seen with grain bleed-through. True, he has not used BB ply, but, he has used cheaper grades of ply without issue. Perhaps the thickness and glue used with iron-on edge banding is the difference, perhaps not. Guess we will find out.
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Old 26th October 2011, 12:56 AM   #992
jdkJake is offline jdkJake  United States
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Default Capping the top and bottom

I wasn't completely sure how I was gonna pull this one off. I really did not want to spend the cash on 48inch pipe clamps mainly because I was not completely sure where I would store them once finished (my garage is already brimming with stuff) or if I would ever use them again.

Surfed the net a bit and got pieces of the idea for the fixture pictured below. Five scrap two-by-fours and a few 3/8inch carriage bolts and I was in business. Worked great and allowed my to reuse my 12inch clamps.

Initial layer of cap material is applied.
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Old 26th October 2011, 01:03 AM   #993
jdkJake is offline jdkJake  United States
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Default Adding a layer of material to the backs

So far, the overlay technique is working out well. I am just rough cutting the material and then flush trimming the final piece after glue up. This works really fast. Much faster than the precision cuts required to make the interior pieces identical. Covers the underlying seams nicely.

The pics are the backs being thickened to the full inch of material. Also broke out the fixture to clamp another layer on for the bottom.

Big problem now is that they are starting to get heavy!

Oh well, just need the front and top panels as well as the final sides to complete the cabinets. My veneer showed up today, so, that will be a completely new adventure as well. Can't wait.
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Old 30th October 2011, 03:29 PM   #994
jdkJake is offline jdkJake  United States
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Default Error on New Front Panel Drawing

Joe,

I found an error on the revised front panel drawing. The distance from the top of the panel to the mid-point of the top mounting hole should be 118mm vice the 114mm as shown (see attached annotated drawing). As currently specified, the alignment of the front panel is off by 4mm the entire distance of the front panel with regard to the sub-front panel.

Please correct soonest.

Thanks.
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Old 1st November 2011, 12:33 AM   #995
jdkJake is offline jdkJake  United States
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Default Additional layer on the bottom panel

Trimmed up the additional layer on the bottom. The overlapping seams work well. In the end, those side seams will be completely covered by the final side panels, so, you will not see any of those joints.
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Old 1st November 2011, 12:42 AM   #996
jdkJake is offline jdkJake  United States
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Default Constructing the layered front panel

Cut and mitered the front panel using a champher bit. I had a steel bit on hand, but, in hind sight, I should have gone and bought a carbide. The steel bit struggled and scorched the wood a bit. Nothing too bad, but, the process could have gone better (mostly smoother). I also constructed the additional 1/4inch MDF cheater panel needed to bring the total thickness to 3/4inch.

Measured out the centers for the holes and glued up the pieces to build up the composite front panel. Yes, they are slightly oversized to support the flush trim technique that has worked so well (thus far anyway).

Bring on the Jasper Jig....
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Old 2nd November 2011, 01:13 AM   #997
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Great pics!
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Old 6th November 2011, 05:56 AM   #998
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Default Hamlets

Hi all started on the hamlets today so i took a couple photos,also added one of my new stereo room which needs some more furniture/rugs etc.

Any body remember the size of the port, i had a look threw the entire post a while back and i,m pretty sure it was never decided upon.

Any suggestion ideas wishes to the placement of port/wiring terminals etc

I made the front panel larger so there will be no visible joins etc,reduced the other panels by 18mm to suit.
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Old 6th November 2011, 06:37 PM   #999
jdkJake is offline jdkJake  United States
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Quote:
Originally Posted by spoonted View Post
I made the front panel larger so there will be no visible joins etc,reduced the other panels by 18mm to suit.
Looking good. Does this mean you are using 18mm material vice 24mm material?

I could not find any final value for the port size either. I do not believe it was ever calculated.

A dedicated listening room huh? Nice. Wish I had the room for a decanted space.
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Old 7th November 2011, 12:20 AM   #1000
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Quote:
Originally Posted by jdkJake View Post
Looking good. Does this mean you are using 18mm material vice 24mm material?
A dedicated listening room huh? Nice. Wish I had the room for a decanted space.
Its still the same as the elsinores 24mm just changed the front panel dimension (ie increased its size so it goes to the edge and can be flush trimmed asi think you have done ) to suit the mk5 waveguide and give a cleaner look.

Same as you have done but i will just glue and screw down no rebate.

I,ll keep it simple without special tools etc as per Joes original idea.

Cutting List
25mm MDF
616 x 230 x 6 back panel/brace /sub panel
616 x 50 x 4 back braces
616 x 362 x 4 top/bottom
362 x 280 x 4 sides
230 x 200 x 2 tweeter stiffening

18mm MDF 666 x 280 x 2 Front panel
(You can add extra couple of mm to flush trim.)


Edited per request of member
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