If I did it again? Tips from those who've done it?

[Mattlock]

About to begin my first Sonosub DIY project.

Was wondering if anyone had any sage advice on what 1) they would do different or 2) what they didnt expect to happen during their "build".

thanks
Matt

[Darren]

I've never built a sonosub but can offer a little advice as I have built dozens of speaker designs and have built many subwoofers.

1. Buy more amp than you think you need. Might consider a pro amp, more versitile.
2. Buy a few tools (if you don't already own them) that will make your life easy with the circles.
--a. A good router (2.25hp or so I recommened Porter Cable but get what you can afford or makes sense to your budget)
--b. buy or make a Jasper Jig (circle cutting jig for your router)
--c. get a good rabbet and/or plunge cut bit for the router for recesses
--d. get some 30" or better clamps
3. Do not use nails or screws in MDF, you may get away with it if you are good but there is no need to risk splitting. A good joint and standard yellow wood glue is all you need to make a joint that will be stronger than the material itself.

4. Have as much fun as possible.

[Mattlock]

thanks Darren, All good advice...

[Darren]

I'm surprised we don't have more tips by now.

[Sonnie]

Well... are we looking for tips... or simply what we would do different than what we did last time? It may be that not many would do anything different or not many ran into anything they didn't expect.

A "Tips on DIY Subwoofer Projects" thread might be a good idea.

[Darren]

Hm... yup. Maybe a Tips and tricks sticky.

Tip #1 - Yes, you do want the bigger (insert driver or amp or both here )

It really might be a good idea.

[Geoff St. Germain]

I'd look into using PL Premium polyurethane construction adhesive rather than yellow wood glue. It expands as it cures and fills without the need for using a sealant on the joints afterward.

[Darren]

Personally, as a woodworker I'd prefer that people cut straight and square joints and use yellow glue. The poly glue just fills the voids of a poor cut and won't be nearly as strong as a wood glue in a good square cut. If one doesn't have the appropriate tools to ensure good cuts then the poly might be a good alternative.

[Geoff St. Germain]

In my experience the construction adhesive works better on cabinets than yellow glue, especially when dealing with plywood. On my guitars I use aliphatic resin (yellow stuff). YMMV.

[FlashJim]

Darren wrote:

I'm surprised we don't have more tips by now.

I've never built a sonosub. No advice here.

[FlashJim]

I'm not a fan of poly glue because of the expansion. I use Titebond II exclusively for my woodworking.

[Chrisbee]

You can cut nice circles with the cheapest of electric routers using a center pin at the correct radius.

I just drilled a hole in a piece of metal angle in place of the straight line fence and pushed a tight fitting masonry nail though the hole.

Then I tapped the nail into the center of my carefully marked circle with a hammer.

The router can't stray from the circle unless something goes very wrong. (like the center nail pulling out!)

I use a home made beam compass to mark the circle and can tell instantly if the router starts to wander from the line. My beam compass has a fixed pencil holder and an adjustable slider for the pin which can be locked anywhere along an aluminium bar. Even a piece of batten with a nail as a center pin and a pencil held tight with lots of rubber bands would do at a pinch. Kids junior school compasses can be canibalised for better pencil holders.

My drawn circle allows me to micro-adjust the diameter of the cut. I take a light cut which barely marks the wood. Then (if necessary) I readjust the router cutting diameter and try again without increasing the depth of cut.

Only when I'm happy do I tighten the radius bar locking screws firmly and proceed to cut in small stages of depth so as not to overheat the cheap Chinese cutter or the router itself.

I bought an expensive Bosch 1300 router later on but the center pin design is completely hopeless and I will have to modify it. If it was ever used as-is for circle cutting in R&D then it must have been a Friday afternoon before the holidays!

Support the underside of your cut circle with scrap wood so it doesn't fall in at the last moment!