I used finger joints, which stink in plywood, and my jig kept slipping (the epic story is detailed here http://ampgarage.com/forum/viewtopic.php?t=25605). So some of the finger joints are all screwy and need to be filled. I glued & screwed a some braces inside to add extra glue surface for strength to make up for the weaker finger joints.
I did all the glue-up with Titebond wood glue instead of epoxy, just easier to deal with. I'll still fill the ruined finger joints and other surface imperfections with wood-flour-thickened epoxy though, that'll adhere way better than any wood filler I can think of.
Questions I have:
a. I will be rear-mounting the speakers to the baffle. I messed up and did a 3/4" setback instead of 1", so the 11/16" plywood will be nearly flush with the cabinet, or probably exactly flush with the thickness of the grill cloth added in. Is that a big deal? Should I find some 1/2" plywood for the baffle? Mostly a cosmetic issue, I imagine.
b. Would piping look good with a flush surface like that? Guessing probably not
c. What's the preferred method for attaching the speakers? Screwing directly into the plywood, or using those T nuts ? If T nuts, should I use a Forstner bit so the nut is recessed flush into the plywood?
d. Any ideas on how to cut a perfectly square hole? My hand-cutting with the jig saw for the handle cutouts was less than impressive
Anyhow, picture below:
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