Single SI HT 18 build

Thanks for the kind words everyone. I think the key for me is to take it slow. As much as I want to hear the end result I really just enjoy making things. Im already thinking about some new mains and a new center. The mains Im using were my first DIY speaker project and I think they turned out good, but they were designed more for music. In heavy duty HT use they could use more power handling, they would make great surrounds though.
Pics:
Still gluing up the bracing

Getting there. Im surprised so far with the fit. Im using a $300 table saw and a circular saw, not exactly the best tools for accuracy. Still, I've had no major problems.

Gluing up the other side panel.

From the back. I used titebond III for all the bracing on to one side and the top(along with lots of 2.5" deck screws) because it was easy to use, but for the other side I used Locite PL fast grab premium. That stuff is like concrete, but I thought it would fill any slight cracks better. Im happy the way it worked, theres a nice bead on all inside seams, though I'll probably still go over everything with caulking just in case.

I'll try to get the back on tomorrow, maybe get some caulking in.

The reason I say I'm just learning woodworking is that my grandfather was a master woodworker. My use of butt joints and screws as clamping would have appalled him. He was highly skilled at joinery. Dovetails and stuff that barely needed glue. I doubt he ever used MDF in his life. I also doubt he could have imagined someone wanting an 18" 900 watt high excursion subwoofer in their home. I have no doubt though he could have crafted it with much more skill than I could ever dream of.

For the bracing I started by cutting all pieces slightly oversized as its really hard to cut them exact in the first place, also its hard to keep the glue super clean on the edges. After they dry I then trim them on all sides on the table saw to the exact sizes. Then I just used a jig saw to cut out the middle to the desired shape, then used a plunge router with a 1\2" round over bit for all the inside edges. I glued them in in stages so that I could maintain square using clamps where possible and 2.5 inch deck screws everywhere else. First I clamp the brace in place with no glue, then drill pilot holes for the screws, screw in the screws, then pull them out and take off the clamps. I then apply glue to the brace then reinsert the screws, this pulls them back nicely to where they should be. Then I reapply the clamps. Rinse and repeat for all brace pieces.

Got the back on today. I forgot to take a pic until it was on and I had it caulked up. Yeah, I got a little carried away with the caulking.

Thats all I got done today as I had some work to do as well as watch my Broncos lose in double overtime.:sad:
I plan on cutting the baffle tomorrow.

Worked on the baffle today. First I clamped all 3 pieces together then drilled pilot holes and screwed in screws without glue for attaching the outside mdf piece to the inside plywood pieces that I had already glued together. I then routed out the woofer holes using the same center pivot point.

Since my model 200 Jasper jig only goes up to 18 3/16" I had to do some modding to get it to the 18 5/8" needed for the outside baffle cut.

Getting set up

This is the outside baffle piece cut out. I removed it from the inside pieces as this cut out is bigger than the hole that I will cut out of the the rest of the baffle.

This is the 2 layered plywood inner baffle cut out and set on the box. Note the ring around the hole. I got the previous cut just a hair too deep. No big deal though.

This is with the outside piece laid on.

Test fit. I went with 16 5/8" for the inside cut.

Fits perfect

With the outside piece on.

Im thinking of using a 1/8" roundover bit on the outside cutout. Then I need to decide whether to use t-nuts or just screws to attach the woofer. In another thread I asked for opinions on this and got some good advice. I ordered a 1/4" heavy duty t-nut kit from parts express so I have it if I go that way, but it definitely adds another step to the build. After I get that done I'll drill holes for the binding posts, give it a good vac job, add poly fill, then glue on the baffle. I wish I didnt have to work tomorrow.