The End Game
All parts are now prepped and ready, so it’s time to finish.
In the following examples, note that I’m using miter joints, but for clarity the internal bracing is not shown.
If employing either the miter or butt joint construction method, remember to add the internal bracing before placing the final side plate – it won’t be possible to fit them through the baffle holes after it’s assembled.
In Figure 7, note that I always start with the baffle first, and assemble around it.
I keep a few small pieces with dado cuts using the same depth as the top and bottom to use as alignment guides to help center the baffle before stapling it in place.
The sides can be used but they are un-steady, so I use small parts instead.
Use a pneumatic staple gun for proper assembly with a 1.25-inch staple, the preferred method of all manufacturers.
Don’t use screws unless you want to drill pilot holes for each screw in order to avoid splitting the wood.
In Figures 8 and 9, the top and bottom are added, while in Figures 10 and 11, the sides are completed.
To finish the main structure of the cabinet, add the other side, as shown in Figure 12.
In this design, I allow for a metal grill by adding a railing around the baffle as seen in Figure 13.
It’s a good idea to use a generous amount of glue when assembling, but don’t be sloppy because when adding these final grill mounts, you don’t want to be scraping out dried glue in order to make the mounts fit correctly.
Once the assembly is completed, a belt sander can be used to clean up and level out the edges before adding a radius.
And there you have it – you should now be able to build your own wedges.
Please keep in mind that this is a quick reference overview, and I glossed over notable aspects like size and measurement.
Remember, there are many ways to build enclosures.
But based upon 20 years of work in this field, the techniques shown here guarantee strength, accuracy, and repeatability. So enjoy, and watch those fingers!
Jeffrey A. Forsburg has been designing loudspeakers for three decades.