The 2 amp Bosch router with Freud bits carved through the plywood like butter. The laminate bit took care of all the protruding edges and I had a lot of fun with the round-over bit. Even routed a cool flared port on the front baffle of the cabinet. The port was extended behind the baffle with a couple of wooden blocks.

Aside from the router, there was a couple of other things I discoved on this project. 600 and 800 grit sandpaper do make a difference. If you work your way through the 100, 150, and 220 grit to the 600 and 800 stuff, you get a finish like glass. The second thing I discovered was varnish paste. I'm never picking up a brush again. This stuff worked just like car wax. Rub it on, and wipe off excess. Let it dry for about an hour and buff with a buffing cloth. No dust or brush marks. Brilliant!

I've added a few photos to the OnePi library.

Gar.

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