First Festool project

[BigHonu]

I have been wanting to redo my subwoofer enclosure for my small tv area for awhile now, and decided it would be a good opportunity to break in the new tools.

Here is my OLD downward firing sealed box.  The extra strip of MDF going down one side of the box was my attempt at covering up an error.  Along with the bad paint job, screw holes that weren't filled in correctly, and the sharp edges, I didn't care for that box too much.

On to the new one!  New design is a slot-port tuned to 19.5hz.

TS55 is great a breaking down the 3/4 inch ply.  Thanks to Brice for the idea of putting a label with the cut depth settings for various widths of stock on the side of the saw.

All the panels are cut out.  It is great that the edges are clean and square with minimal tearout.  Makes the assembly that much easier.

Trying out the new Kreg Mini jig.  Pocket holes are drilled out.

The dry fit looks pretty good.

With my homemade circle jig, I'm cutting out the hole in the baffle for the driver.  Incidentally, this experience with the PC in all of it's dust making glory, spurred me to get to OF1400.

The glue-up underway.  Notice my high tech 'clamps'.  I figured that glue, along with the pocket screws would make a decent enough joint.

With the glue all dry, I use my newly acquired 1400 to clean up the box before I can get on to sanding.

Did some flush-trimming...

and used a 1/4 inch round over bit to soften up the edges a bit.  Yes, I do need to practice more!

Going through some sanding with the ETS125

I guess my skills with the pocket screws were sub-optimal as some of the panels became slightly askew.  This is the result when trying to flush everything up using the sander.  I definitely need to learn different joinery methods.

Luckily, I was using General Finishes Black stain so all of those mistakes are hidden up pretty well.  Using three coats of the stuff definitely helps.

I wiped on three coats of Arm-R-Seal, and after everything dried up, installed the driver, and here it is ready to move into its space on the other side of the couch.  It also doubles as an end table.

Thanks for letting me share my small project!

BTW, any tips to help with my woodworking skills are DEFINITELY welcome!

 

[rookie08]

Nice job!  Looks really good!

Great to use it as an end table as well;

though you might spill your drink over with all those huge bass tones.  [laughing]

Cheers!

 

[jmbfestool]

Nice.

Maybe use a Domino helps keep it flush.

JMB

 

[mattfc]

I guess my skills with the pocket screws were sub-optimal as some of the panels became slightly askew.  This is the result when trying to flush everything up using the sander.  I definitely need to learn different joinery methods.
BTW, any tips to help with my woodworking skills are DEFINITELY welcome!

Pocket screws pull at an angle, so critical to clamp both pieces tight and you should be able to avoid alignment errors

 

[BigHonu]

Thanks!

rookie08,

Surprisingly, it doesn't move stuff on top of it around that much unless I have it turned up pretty loud...but then again, at those levels, the other stuff rattling around the room make more noise!  [eek]    

JMB,

Thanks for the suggestion on the Domino. That would be ideal, but I am having a hard time justifying the cost of one just for weekend warrior use.  I'll try learning some rabbet/dado joints then maybe try out some stuff with dowels.  If I ever get to a point where I'm doing this on a more regular basis, maybe the Domino will work its way into the 'workshop'.

mattfc,

Yeah, greatly underestimated how much the panels move while you are putting the pocket screws in.  I thought I had those panels clamped down properly, but apparently not.

 

[honeydoman]

Aloha!  Fun project and anything to do with rock and roll makes for a nice project. Crank up the ventures!  (Hawaii five O)

Good job

 

[harry_]

after you use the pocket hole system you you can also hold back the panel by a little bit and use the screw to 'suck it flush'. Of course it is hard to beat the alignment of a domino or secure and proper clamping. But sometimes we gotta do what we gotta do with what's on hand. With some practice you will learn how much you can hold back to get good alignment and how to work the glue to keep from making a mess when the panel slides into place.

Good job & good luck!

 

[Rob-GB]

Big Honu, if I might suggest get a biscuit slotting cutter for the OF1400, most router bit people make them, and that would really help with alignment issues.
I say this because that is what I used for a couple years before I could justify a biscuit jointer. It would be a low cost option while you save up for the Domino  ;D

Nice project by the way, I keep looking at the plastic laminated box my sub is in and thinking I can make something much nicer for it.  [embarassed]

Rob.

 

[BigHonu]

Thanks for all of the tips! 

I didn't even know there was a biscuit slotting cutter bit! 

 

[Notorious T.O.D.]

Nice work!!!  My only question is the use of plywood for the enclosure...we always used particle board for the weight and density...being as much glue as wood or so it seemed.  One of my first woodworking projects was a pair of hexagon tower ported speakers that took me through college and beyond....but that was 30 years ago...

Best,
Todd

 

[BigHonu]

Nice work!!!  My only question is the use of plywood for the enclosure...we always used particle board for the weight and density...being as much glue as wood or so it seemed.  One of my first woodworking projects was a pair of hexagon tower ported speakers that took me through college and beyond....but that was 30 years ago...

Best,
Todd

Todd,

Thanks!  My wife was asking when I was going to make another one to go on the other end of the couch. Gotta like that!

Ply vs MDF seems to be a big topic on all of the diy speaker forums with no clear choice when it comes to subs.  Seems that the only consensus is that ply gets the nod when you need to move the speaker around a lot as it is lighter and holds up to bumps better, and MDF is preferred for stationary aplications and is generally cheaper and easier to finish.

Sonically, people claim to hear a difference due to the resonaces of the box, but others will claim that a properly braced box will keep those resonances under control.  Having used both materials, and listening to both boxes, I don't have an opinion either way.  They both sound fine to me.  Besides, there are enough plastic toys and other stuff in the room that rattle and make way more noise than any unwanted resonances the box creates.  Heck, I can even get the dishes in the adjacent kitchen clattering away at times.  [scared] [eek]

One thing is for certain however, and that is I hate the MDF dust, so for me, it is ply all the way.

 

[harry_]

Whats MDF dust ??? I use Festool. I gots no stinkin dust. [big grin]

 

[BigHonu]

Whats MDF dust ??? I use Festool. I gots no stinkin dust. [big grin]

You caught me on that one! Ha!