- Enclosure Construction & Assembly -
This is where the fun begins. To date, the biggest speakers I had built were about 30 inches high, made with 5/8" particle board and no bracing. So the thought "Am I biting off more than I can chew?" crossed my mind multiple times. I had recently purchased a Circle Jig because I was also going to be flush mounting my Vifa's, something else I had never done and something that can be pretty difficult with just a saber saw.
Overall cabinet size was 51" (including bases) x 12" x 12". The woofer chamber ended up being about 1.7 feet cubed for both, and the mid chamber ended up being smaller than planned ,but that didn't affect much due to the 450Hz filter. The divider between the chambers was also 1-1/2" thick and I placed two 3" scraps in the lower section for added bracing. Everything was glued, sides were screwed with the least amount of screws possible, just to hold it in place while the glue dried overnight. After the spackle had dried and been sanded, everything was ready for paint. I used old PE catalogs to stand the cabs off the ground just enough to get underneath them as far as I needed, and everything was primed with two coats and sprayed with flat black enamel, again two coats. After the paint had dried it was down to adding vinyl, which I was nervous about doing, and installing everything. The vinyl went perfectly, after taking advise from Darren, and the speakers went smoothly with no problems. Everything was finished around 2:45 AM.
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