Back in my kit making days, the method for making a fabric
grille was to staple some velcro on the cabinet, then
stretch the fabric over the grilled frame by spray gluing
one side, the opposite side,a third , a foe\urth and finally
pull tight at the edges.

but I'd like to get the discussion started at making the frame
for scratch build. I have failed at trying to cut quarter
round stock in a 2 cent mitre box. Nothing is square and
_besides that the sides don't line up worth squat either.

There are hand miter box systems with the saw which I've
seen, but don't kniow what level of improvement would be
provided over the old wood one. The saw looks nice and the
blade is like a hack saw blade only wider and should cut
square.

I thought of using a length of picture framing material.

Then there's the 'chord system' where the fabric is
pressed into a groove and the rope chord is forced in to
keep it in place.

I would use silk fabric because it is sound neutral.

Fastening the frame to the cabinet is usually done
with those ball and socket thingies, magnets, or the ol' velcro.
With the last kits I built, the ball and socket thingies sucked
and the pre-drilled holes to line everything up sucked too.

What methods are being used here that give an at least
bearable and at best professional look?

BTW... new info in the Group build Plug and Play speakers too.

Position the frame on the baffle and tape it in place. Drill a very small hole through the frame into the baffle where the mounting plug things will go. Then use the hole as astarting guide for drilling the actual size holes. That eliminates the positioning dilemma.

Spray the front and sides of the frame with PAM vegetable oil spray. Place the fabric on a table, put the frame over it upside down and cover the exposed part of the fabric with newspaper. Now spray the inside part of the frame with 3M 90 adhesive. Let it develop a "tack" and, beginning at the middle of one long side position the fabric in the glue. The PAM allows the fabric to slide and keeps the visible part out of the glue. Stretch and place the other long side, then the 2 short sides leaving all the corners for last. Trim away as much of the bunched fabric in the corners as possible with a scissors.

You will get some glue on the visible parts so don't use a light color fabric.

I will never use this method again HAH! but instead rout a dado all the way around the frame and place the fabric with rubber screen spline.

Hah!

Can you say more about the screen spline method...
or does it speak for itself, so to speak?

Any link possible that will show the grille-making process.

signed,

lon (Mr. Spoonfed)

• Spoonfed instructions

Ok, let me ask it another way. What is the router bit used
for the 'screen chord' technique and how is the the chord pressed
into the groove?

• Deadly good mitersaw by Veritas