Puff Head
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Box Building Tutorial!
Ok,here it is.I will update it at a later time with more pics/info.Feel free to post any questions.
Today I will show you how to build an enclosure.I try to do the best I can when writing stuff.If something isn't clear, or you have any questions, just ask.
Materials & Tools Needed: Table Saw (circular saw will do)
Router (jigsaw will do)
Power Drill
Drill bits
Various Sized clamps
3/4" MDF
2" Drywall Screws
Woodglue (not gorilla glue)
Liquid Nails (silicone will do)
Resperator (mainly if carpeting)
Protective Eyeware
If you are carpeting the enclosure, I recommend using contact cement.Down the road, the carpet will not fall off.That's the biggest weakness of the spray adheisive.That and the price.A can of contact cement is approximately a quarter of the price of the spray adheisive.Now that we have that down, let's get started!
First you'll need a sheet (sometimes two) of 3/4" MDF.This is just my suggestion.I do not recommend using MDF for full range designs, as you can get some nasty sounds.But we're not doing full range right now.
Next, you'll need misc. supplies and tools.The main key to a good box is nice cuts.I personally use a table saw for my cuts.You can use a circular saw and a straight edge, but it takes much longer.You can also get your wood cut at Home Depot, or Lowes.But, don't expect the cuts to be perfect unless you know the person cutting.I've seen cuts that are supposed to be 16.5" x 16.5" turn out to be 16.25" x 14 3/8".However you do it, safety is the key.Be careful and wear the proper protection.I even recommend ear plugs.
Once you have your wood cut, I recommend using a labeling system.I use lettters and/or numbers.I tried lining these up good, but at the time I took the pic I was in a hurry.Maybe next time I'll line up all the pieces perfect for a nice shot.
Depending on your box, it may help you to do a lay-out with tape and remove it as you go.If you do this be sure to use 3/4" tape.
Now, take your wood glue and apply a decent amount to each piece.I currently do not have a pic of this but will within a week.Use your clamps and clamp it into place, pre-drill a couple screw holes and screw a couple screws in if you need the clamps for the rest.I've built boxes without clamps and screws before, so don't sweat it if you don't have either.
With MDF you MUST pre-drill before putting a screw in, or the wood will split.I will do a couple tests and take pics tomorrow.
Basically you just repeat those steps over and over.I will get more pictures soon.
I usually do the cut-out once the box is assembled, but if you're not 100% confident in your circle cutting abilities I recommend doing it before you attach it to the rest of the enclosure.
Next step is to seal it up.I personally use liquid nails.The fumes can be overbearing the first few times you use it which is why I recommend using a resperator.I've gotten "buzzed" a couple of times off of it because I was too lazy to find my resperator.All you're doing is choking off the oxygen supply to your brain.So be smart.I usually just barely cut the tip off of the liquid nails to run a thin
bead all around the inside of the enclosure.When possible I do this for the top, but with complicated designs, I have to do it from the outside.Doesn't matter as long as it is sealed up good 
If you feel like it, you can even slap some on your finger and apply it that way.But, if you do go this route, I highly recommend wearing gloves.Liquid nails does NOT come off of your skin easily.Or clothes & carpet for that matter.
Hopefully your box will look good, and sound even better
Last edited by Puff Head, 1/28/2006, 12:06 pm
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See the stick? Fetch the stick!Stick stupid!Eh, no wonder why you're extinct.
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1/28/2006, 12:05 pm
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