Build A Pair of Stereo Speakers

Step 6 Assembling The Box

There are numerous methods one could use to assemble these boxes. Gluing and then clamping the sides together is probably the easiest and most common way.

I will be using an alternate method which consists screwing rather than gluing. For this method the two materials needed are 5/4" wood screws and plenty of 1" by 1" which we will cut to appropriate lengths.

Basically what we will do is wedge lengths of 1" x 1" into the corners of the box and then use screws to hold the sides together through the 1" x 1". Here are specific steps:

1) Cut the 1" x 1" into lengths that fit along the corners of the inside of the box.
2) Drill screw holes into each piece. Usually 4 (2 at each end, perpendicular to each other on adjacent sides). The size of these holes should be big enough for the screws to slip.
3) Clamp the box together as it should be when assembled. Lay the lengths of 1" x 1" into their appropriate positions then mark where to drill into the particle board. You can do this by poking a skinny pencil through the holes already drilled into the 1" x 1".
4) Take away the 1" x 1" pieces and drill the holes marked on the particle board with a smaller bit which allow the screws to grip.
5) Put the 1" x 1" pieces back into their same positions then screw together the box.

Do not worry if the sides don't match up perfectly or if there are slight gaps in the joints; we will deal with this in later steps. If the steps seemed confusing refer to the pictures to clarify (I'm a visual learner so pictures help me a lot).