Posted by Bill Epstein [ 65.189.210.168 ] on November 20, 2005 at 15:38:48:
Late to the thead below but visiting with Steve and seeing GarMans incredible Winbraces I thought I'd show what I think is a simple and easy way to double the front baffle and "embrace" the woofer:
I cut the inner baffle piece a little over-size to flush-trim with the router after glue-up in case of slippage.
Clamping the 2 together I drill the pilot hole for the Jasper pin through both. Then rout the appropriate size hole in inner and outer.
For glue-up I place the woofer in the inner baffle to correctly locate the outer baffle. I protect the edges from glue with wax paper. Smear up with PVA glue and drive home a buncha' screws I'll remove later.
Next day flush trim the edges of the inner to match the outer baffle.
Now I'm thinking about sizing the inner baffle to make a rabbet so it slips inside the box. Maybe.
I do the same to mount the ports so the black schedule 40 pipe doesn't show. Now I've seen how nice the plastic flared ports look I'm re-thinking that.
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