[JDRoberts]

adamt wrote:

Here is the raw materials list
1-4x8 sheet of 3/4" MDF for endcaps
I will not be putting anything on the top over the port. So I have the foot plate, 3 for the driver location and 3 for the port location.
5' piece of 24" sonotube,
3' piece of 6" PVC pipe for the port.

I would add-

sound deadening material for the inside

some type of dowel for the legs.

spray glue,for inside insulation/outside covering.I ended up using @ 2 large cans.

primer and paint for the caps.

liquid nails to adhere the MDF together and to the tube.I used 1 full caulk tube for my sono.
EDIT: another thing,how are you going to be cutting the tube?
remember,you need to make 2 square (to one another)cuts,as the tube will probably be a little boogered up on the ends from handling.I used builders paper wrapped around the tube to make straight and square lines to cut along.

adamt wrote:

1. Cut 4 circles at 1'-10" for the inside diameter of the sonotube.

I used 23 1/2" for the inside pieces.seems to fit snugly,without being"beat it in with a hammer"tight.

adamt wrote:

2. Cut 3 circles at 1'-11 5/8" for the outside end caps and the floor plate.

The end caps I made 27" for 1 1/2" of overhang. @ 23 5/8" the cap will be smaller than the 24" OD of the sonotube.

adamt wrote:

3. Cut the recess circle out of a 1'11-5/8" piece then make the woofer cut out. I'm not sure how big these cut outs will be yet but I will have the dimensions once I get the driver.

What Driver are you using?you may be able to look up the figures on the MFG's website.

adamt wrote:

4. Make 2 more woofer cut outs on two of the 1'-10" boards. The driver location cuts are finished here. Glue these three pieces of wood together? What about a chamfer cut?

I used a 1/4 round over on all edges,top and bottom.this makes a small space for the glue.

adamt wrote:

5. Cut out a 6 3/8"(outside diameter of port) circle on the other two 1'-10" boards
6. Cut out a 6"(inside port diameter) circle on one of the 1'-11 5/8" boards. Round the cut out with a 3/4" round over bit. The port location cuts are finished. Glue these three pieces together?

Liquid nails is your friend!! LOL.
don't forget,if you use LN,it's kinda thick,so when you glue the boards together put some weight on it to compress the pieces together.(I used a leftover piece of sono to line up all the pieces when I glued them)

adamt wrote:

That's all I really know at this point. What's the best way to secure the end caps to the sonotube?

you guessed it-I used LN.

adamt wrote:

And how about attaching the footplate to the bottom driver plate?

I used 1 1/4" dowel cut into 6- 5" tall legs.I marked the spots for the legs using a protractor-a mark every 60 degrees.the center for the legs I put 1 1/2" in form the outside so the screw heads would be covered by the sonotube.( the screw goes into the channel the sono sits in.)
I attatched the legs to the plates with 2 1/2" Teflon coated screws.the teflon makes them twist in a little easier.that and drill pilot holes.

adamt wrote:

I will probably be picking up the first round of supplies tomorrow and start making the cuts for the end caps. I will post pics when I make some progress. Ordering the gear will come when I get the extra tuition money from my school. Probably a couple weeks or so. If anybody could add to this I would appreciate it.
Adam

I'm going to be doing another build as soon as my other driver gets here(later this week)
I'm sure I'll remember something I forgot to add.
I'm also sure the other guys will remember more stuff I forgot.