Welcome to Adobe GoLive 6

Manufacturing the Parts

Making the parts of the box with MDF is an exercise in how well one handles the pieces of MDF. The corners are easily damaged and one needs to be very careful about how you handle the pieces and store the pieces.

MDF handipanels are not exactly 24 inches wide. I measured mine pieces to vary from 23 15/16 to 24 1/16 in width. This required me to make sure the 24 inch pieces were cut to width as well as length.

When cutting the 22 1/2 inch widths of the front, back, sides, and inner brace I found it to be very helpful to make all of these cuts at the same time on the table saw, which makes them all the same size. The same went for the 24 inch cuts on the front, back, top and bottom. A circular saw can be used as well as a table saw. It is recommended that you use a guide when sawing the MDF with a circular saw.

The front and back braces were made 22 7/16 inches long rather than the 22 1/5 inches one would expect from the drawings. This allows the braces to be glued up prior to final assembly on the front and back. The extra 1/16 of space allows the brace to be glued, but not interfere with final assembly.

The holes were made by laying out the design on the bottom and inner brace, then cutting the holes are described in the cutting holes section. For the plate amp use the saber saw.

Home

Introduction

Project overview

Bill of Materials & Costs

Material Properties

Cutting Holes

T Nuts

Manufacturing the parts

Cut List

Top and Bottom Pieces

Dry fit the front and back braces using a scrap piece of MDF on either side to ensure that there is a little space left to insert for final assembly.

Dry fit the pieces to see they make a good box. I find that it is a lot easier to sand down an MDF edge by 1/16 inch rather than sand a 24 by 22 1/2 inch surface a 1/16 of and inch.

Make any final adjustments for size as needed. Small gaps if you are using a circular saw will be sealed with the glue. Large gaps are another issue all together. Make sure the Precision Ports fit through their respective holes, especially in the inner brace.

Once you are satisfied with the dry fit, mark the location of the inner brace on the front, back, and sides.