Since this cabinet is for portable and sometimes unpredictable pro-sound use, we want to use a high-quality "Baltic Birch" type plywood, which is very rigid due to its 13-layer construction. I found a 3/4" 11-layer plywood at my local lumber center, and while technically not Baltic Birch, it had near-identical properties and characteristics. It ran about $35.00 for a 4' x 8' sheet, which is enough to build a pair of these cabinets. Please visit the website for detailed drawings, panel dimensions, and cut sheets.

I chose to assemble the cabinet using biscuits and glue for the majority of the joints, which makes the cabinet very rigid. The side panels were glued together fi rst, and then I attached the end caps to both ends. The front baffl e was designed as a separate panel, and is secured into the cabinet via screws driven into a series of 1" x 1" stringers running behind the edge of the baffl e. This makes it easy to cut or modify the driver cutouts and allows the baffl e to be removed from the cabinet if necessary. All outside edges and corners were rounded with a router and 3/8" roundover bit.