Step 3: Anchor Supports To Baffle
With the top cap fitted on the baffle mark 2 points, 2 inches apart, 3/4 inch down from the top of the cap on one side of the cap. Repeat this on the exact opposite side of the cap - these will be the points that will anchor the cap to the baffle to the support.
With the center punch and hammer, punch the marked points while the cap is fitted to the baffle - this should transfer the punch to the baffle as well making it easier to drill through both the cap and baffle. If you do not center punch these marks the drill will wander on the surface of the cap making it hard to drill the holes.
Drill Top Anchor Point Holes And Mount Top Support:
With the 3/16 inch drill bit in your power drill, carefully drill the center punched points.
Insert the top support into the baffle by flipping the baffle over and pushing the support down to the top of the baffle. You should align the support such that the anchor holes will line up with the ends of the support such that you will be screwing the anchor screws into the end grain of the support pieces. It is easiest to align the support piece before pushing it down into the baffle. ** Removing the top cap before doing this can help you verify that the support is lined up with the top anchor holes; if you do this when putting the cap back on the baffle ensure that the anchor holes line up.
With the top cap on and the top support in the inside of the baffle, use 4 - 2 1/2 inch #8 deck screws to anchor the cap to the baffle to the support.
Locate, Drill & Anchor Bottom Support:
Insert the 3/4 inch copper pipe into the now anchored top baffle support. Now feed the bottom support down the pipe into the bottom of the baffle ( we do this with the pipe as it will help keep everything in alignment ).
Before pushing the bottom support into the baffle, align the end grains of the support with the screws in the top support - we will use the top support screw locations to mark where to punch, drill and anchor the bottom support.
With the bottom support aligned, and your tape measure ready - push the bottom support into the baffle 12 inches. With a tape measure you should be able to do this fairly accurately - simply push the support down a short ways and measure the distance from the support on the inside of the baffle to the bottom lip - repeat until it is 12 inches inside the baffle. Be sure to keep the alignment of the support when pushing it down - the fact that the copper pipe is running through it's center hole and that of the top support should help with this.
With the support 12 inches up from the bottom of the baffle, lay the assemble on the ground with one set of top anchor screws facing up. With the tape measure on the outside, and the nub fixed over the bottom lip, measure up 12 3/4 inch from the bottom ( should be centered on the end grain of the bottom support ). Keep the tape measure in alignment with one of the top anchor screws and make a mark with a sharpy. Do the same thing for the 3 other anchor points.
With the bottom support anchor points marked, use a hammer and center punch on those marks such that the drill will not wander when trying to drill the holes.
With the 3/16 inch drill bit in the power drill, drill out the bottom anchor holes. Make sure not to drill into the bottom support too far as we want to provide good bite for the screws.
With the holes drilled anchor the bottom support with 4 - 2 1/2 inch #8 deck screws.