These photos are a little out of sync as I was under the impression I had deleted them, anyway these are from a couple of weeks ago when we started on Russell's 'rough' box. The infamous Festool track saw, Russell's Router and in the background a biscuit jointer, yet to be used in anger.
The woodmaster himself! We learnt a lot from this early build, mostly how not to do things but it was well worth the effort as the latest boxes really are spot on. Simple things like nailing down the baffle cut-out as well as securing the baffle itself during routing helps prevent any movement when you finally cut through the final piece.
It was a real struggle lining the baffle and end piece up because we measured and cut them seperately. For the next ones we plan to centre drill through both pieces, so the circles will exactly line up. We even discussed gluing the two pieces before making the cuts but are not quite convinced it is necessay. You live you learn
The observant among you will note the proximity of a forklift truck, having moved up to 26mm MDF, this may become quite useful once my box is finished. I can't help thinking Graham could do with it more than me though
It was surprisingly fiddly to glue and assemble the pieces and keep everything located correctly. I am probably going to use biscuit joints to make this process much easier. It is another job but will add to the strength and make the gluing together a bit easier. I also think we learnt some lessons about the amount of glue required!
I quite enjoyed watching this part and trying to work out how Russell got so much glue on his face, worth another shot methinks
Kudos to Russell for going first, someone had to do it and we both learned loads. It might seem wasteful financially to build a 'rough' test box but the lessons were invaluable and have given us greater confidence to move forward with the other boxes.
I think we may well build several versions each to test performance as well as aesthetics. It does help having a skilled professional a few yards away who is only too happy to offer advice.
Hopefully we will get another crack on Wednesday?
Adam