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The way I do it is a little more time consuming and you need the right
stuff, but it works for me. You might find a way to do it easier for
you, but just be sure the box has NO air leaks and is solid!
Ok, I cut my MDF with a table saw, or jig saw, making sure the sides are
straight as an arrow! Be sure to layout how you will adjoin what side to what before you do this so you have the right size pieces!
Also, make sure to account for the material thickness as well! For my first box I 'thought'
I needed a 20 inch side, then realized AFTER I cut it that it needed to be 21 inches....1/2 inch of MDF on either end!
Anyhow, just be careful here with the saw as well. Lost limbs are NOT
Purehonda.com's problem!
What I then do is make sure all the sides fit
ok and mark the tops for
screws. I use drywall screws and Liquid nails. I place the screws along the sides to be attached evenly. I then take a drill bit that is
designed to counter sink a hole, so the tops of the screws will be
flush. Need help on this? Email
me or use the Tech
Forum.
Next I apply liquid nails or wood glue and screw it
together! DON'T use liquid nails or glue on the box lid the one with
the sub holes, you might need to get that top off one day! If you have a nice terminal assembly for the speaker wires cut that
hole out as well. If not, what I've done is drill a hole just big
enough to squeeze a wire through it and then liquid nail the wires in
place.
When cutting out the speaker holes be sure to measure from the INSIDE
edge of the mounting ring - just outside the foam/rubber surround. DON'T make it too big or you'll be in a big mess! After the assembly, I run a
bead of liquid nails along the inside corners of the box - can never be to safe! Let everything dry for at least a
day.
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