Bank Holiday Workin - Day 1 of 4 - Facia

In readyness for this weekend I had arranged to have subs amps and batteries delivered - Connects2 did a cracking job getting them whole lot delivered to work especially.  I was away with work when it all arrived so managed to get some of the guys at work to lug it all in.  Later that day I took Biggy to work and picked it all up

Before

And After

loaded out with all this

I then loaded it all into the house when I got home

10 batteries 8 subs and 7 amps just out of shot on the sofa - Big Black is getting closer to completion!

With the Bank Holiday weekend coming up and a deadline getting closer (due to schedule conflicts - Biggy needs to be with Paul Richardson @ A1 Audio Design to get the front and rear of the box trimmed and tidyied) I have booked tuesday off work giving me 4 days work to do. Today was day 1 and the plan was to make a start on the facia

You may remember i spent a little while cuttin some holes last week - but when it came to align the facia with the rear piece the holes didnt line up - i tracked the problem down to my slightly ghetto cutting Jig so managed to get a better one made and earlier in the week started cutting a new pair of baffles - first job this morning was to finish off cutting holes

I cut the facia on Thursday -

Here you see the new improved router jig - this time using a bolt to centre it rather than the previous one which was screwed to the wood

Action shot!  and yes I know I should be wearing a mask

Both baffles cut and aligned - perfect

time for PVA

And the facia screwed in place

Then in it goes

More Whack a Sprigg action

Some hefty bracket-age!

Once the face was installed we needed to make a start on the port - in order to get a nice smooth rounded edge on the port I thought it would be a good idea to take the 16 circles cut for the face and chop them into quarters - those quarters could then be used as the port by packing them onto of each other - we tried this but found it took up too much port width so we decided on a sensible width for a section of the circles and cut LOTs of them

Here you can see the cut sections starting to be attached - the large post with the notch cut out is a 2x2 post to attach the port pieces to - the notch is to allow the subs to be fitted in

And thisis how it looks now
 - the PU foam is a bit of a mess but it will get tidyied up tomorrow and then sanded smooth