Sealed 15" Dayton DVC385-88 build

I was able to move pretty fast using the table saw. But, if you're not comfortable with this, use a jigsaw--it is safer.
I started with a slice. I placed a mark on the fence, so I'd know when to stop the cut. I flipped the board over and made a second slice.




Then I moved the fence and sliced again.




Followed by a sideways move to clean out the narrow strip in the middle.




I free-handed the angled cuts on the table saw. Again, if you're not comfortable with this, use a jigsaw.
Finally, I lowered the blade and set the fence, then raised the spinning blade into the work piece for the final cut.

I made a lot of holes in the braces today. I wore out the hole saw!




I know it is more bracing than I need, but I like overkill.




It's a start.

In a single step, I glued the internal brace pieces together and glued and clamped one cabinet.
Afterwards, I glued together the second internal brace pieces and called it quits for the day.

I used PL Premium in a makeshift grout bag (1 Quart ZipLock freezer bag, with a corner snipped off) to assemble the brace pieces and to install the bracing inside the cabinet.

I used TiteBond II for cabinet assembly and shot some finishing nails to maintain alignment while installing the clamps.

I wanted to see if I could move faster on the second cabinet. I have used a foam roller to spread Titebond before, but today I wanted to see if I could apply PL Premium with a foam roller. The stuff is pretty thick, but that's okay. It went well.

I put some aluminum foil on some cardboard and used that to load a foam roller with PL Premium and it went so well, so fast, that I used it on all the rest of the cabinet assembly. It was much faster than the makeshift grout-bag method.

Plunge/Route/Plunge/Route until you cut all the way through.




I like to use a Spiral Up-Cut bit for this task, because it lifts much of the chips up and out of the channel as you cut.




Now that the through-hole has been cut through the first baffle layer, I'm gluing on the second layer.

Sand the Feet.




Tint the Feet. Hurry-Up-And-Dry the Feet.




Quality Inspection.




One coat of Crystalac Black. I'll spray another, followed by 3 coats of clear.

Decorative touches, getting sanded by Mrs. Interest.




Sedona Red stain on African Mahogany.

I had a few decorative touches in mind, but the Coolness Factor just wasn't there. Moving on...

Ring grills.




Nearly done.

Re: Sealed 15" Dayton DVC385-88 build

Looks good. I was planning on doing the same style of grill as my drivers jbl gto1514d don't have a nice look to them.



(sample pic, i haven't started my build)