Step 18: The Cabinet, more construction details
The panel dress and top were cut after the rest of the case was assembled and the chassis was fitted. They were then covered with vinyl.
The front panel dress is 1/4 in. plywood.
Front Face / Speaker Baffle
The front was cut from 3/8 in. plywood with a sabre saw. It was traced on a piece of butcher paper, in case the cabinet wasn't quite square. It wasn't traced directly, so that one edge could more accurately be aligned with the "factory edge" of the plywood. The front is large enough to accommodate a 10 in. speaker, if desired.
A small "beam blocker" circle was left in the center, to block the harsh treble that usually projects at a narrow angle straight from the speaker.
Eight holes were drilled and countersunk for the mounting screws. The screws fit very snugly, but were also PVA glued in place.
The grill cloth is undyed burlap; a nice open weave that's very transparent to sound waves.
It was simply wrapped over the front and stapled in the back, carefully. It's easy to keep it tight and straight. No glue was used.
Attaching the Baffle Panel
A bottom cleat, made from a section of 1x2, was added to the cabinet.
The front baffle panel was screwed to the cleat at the bottom, and to the chassis supports at the top. Finishing washer dress up the screws.