Passive Radiator CSS SDX10 Design and Build

[EngineerNate]

 

[mwmkravchenko]

You plan to flush trim the protruding fingers?

Mark

 

[EngineerNate]

You plan to flush trim the protruding fingers?

Mark

Yes, then the cab gets big roundovers.

I needed to flush up one side first with a flush router jig so I can use a standard flush trim bit on the other side of the corners.

 

[EngineerNate]

Very similar to the jig in this video.

Cheers
Nathan

 

[mwmkravchenko]

Used this type of flush cut for over 30 years. If you tune it well it's awesome. The main issues that I have run into are the router, or the bit slipping downwards. I have 6 routers in my shop ( I have run a professional Cabinet shop since 1989 ) and the routers with the split collets hold the bit shanks more securely. Ones that use an ER style are the best, or there is a replacement type that I use in my Makita cordless router. It has 3 slits. Never seems to move for me.


Mark

 

[EngineerNate]

Used this type of flush cut for over 30 years. If you tune it well it's awesome. The main issues that I have run into are the router, or the bit slipping downwards. I have 6 routers in my shop ( I have run a professional Cabinet shop since 1989 ) and the routers with the split collets hold the bit shanks more securely. Ones that use an ER style are the best, or there is a replacement type that I use in my Makita cordless router. It has 3 slits. Never seems to move for me.


Mark

I have a 1/2” shank Bosch router, a 1/4” dewalt cordless, and a very old craftsman 1/4” that was my grandfathers.

I haven’t had any slipping issues with any, but the craftsman the “collet” is built into the end of the shaft so if it wears out it’s done. The other two have separate replaceable ER style collets that I like much better.

The Bosch height adjustment is nicer but the dewalt is just so light and handy, and it does a bang up job for its size.

 

[EngineerNate]

Got the flush cutting done. If this were the final look I’d have setup the router on the router table to prevent those wobbles. As is I can temporarily fill them to avoid the roundover bit following them.

I want to get one of those extended bottom plates for the big router. Would have helped.

Cheers
Nate

 

[mwmkravchenko]

View attachment 514911

View attachment 514912

View attachment 514913

Got the flush cutting done. If this were the final look I’d have setup the router on the router table to prevent those wobbles. As is I can temporarily fill them to avoid the roundover bit following them.

I want to get one of those extended bottom plates for the big router. Would have helped.

Cheers
Nate

Or a quick and dirty router table to slide the enclosures over. That is usually the best surface finish. I make such a router table from the appropriate sized scrap wood, in my shop it's melamine as it is smooth and flat. A few screws from the router base to the sheet and pop a hole through via a router bit. A fence is a straight board with a beunos notchos cutout for chip removal. And two clamps to hold the fence to the base board. I don't have a huge shop. And I already have a dedicated spindle moulder that can do a fair bit, but sometimes it's a router that is what is best.

You are doing a n awesome job sir! Cabinets that are unobtainium commercially.

Mark

 

[EngineerNate]

Or a quick and dirty router table to slide the enclosures over. That is usually the best surface finish. I make such a router table from the appropriate sized scrap wood, in my shop it's melamine as it is smooth and flat. A few screws from the router base to the sheet and pop a hole through via a router bit. A fence is a straight board with a beunos notchos cutout for chip removal. And two clamps to hold the fence to the base board. I don't have a huge shop. And I already have a dedicated spindle moulder that can do a fair bit, but sometimes it's a router that is what is best.

You are doing a n awesome job sir! Cabinets that are unobtainium commercially.

Mark

I bought a portable Ridgid branded work table that has a router base built in specifically to do this, I just didn't want to set it up for cuts I knew I'd be blowing away with the roundovers.

 

[EngineerNate]

Got the top and bottom of the glued up panels squared up and flat. If I do this again I’m starting with a plane. Got my calories in tonight.

 

[mwmkravchenko]

Now that's a workout!

Are you gluing with PL premium?

Mark

 

[EngineerNate]

Now that's a workout!

Are you gluing with PL premium?

Mark

I used pl premium for the bracing joints and title bond II for the panel lamination and box joints.

 

[EngineerNate]

Tops glued on.

 

[mwmkravchenko]

Nice! How do you like that style of fold up support? I have been looking at those for a while. This looks to be fibreglass poles?

Mark

 

[EngineerNate]

Nice! How do you like that style of fold up support? I have been looking at those for a while. This looks to be fibreglass poles?

Mark

It's been great for everything I've thrown at it except for the sanding above. Too much weight moving around.

Hanging some sandbags on the legs helps.

It's been really convenient to have.

 

[EngineerNate]

We have six sides.

 

[mwmkravchenko]

We have six sides.

Now it's getting serious.

Now you whip out your 1 1/2" radius and go to it!

Mark

 

[EngineerNate]

Now it's getting serious.

Now you whip out your 1 1/2" radius and go to it!

Mark

The ply is a little under 3/4 I think per layer so I’m probably going to do 1 1/4 so I don’t cut past the edge of the box joints.

 

[mwmkravchenko]

The ply is a little under 3/4 I think per layer so I’m probably going to do 1 1/4 so I don’t cut past the edge of the box joints.

You know that I'm teasing. I have a few router bits that size. They are confined to the spindle moulder. I tried one on my router once. Too crazy!

Mark

 

[EngineerNate]

You know that I'm teasing. I have a few router bits that size. They are confined to the spindle moulder. I tried one on my router once. Too crazy!

Mark

I have a 1 1/2 router bit.

My plan is just to take a lot of passes with the 1 1/4 bit with the router mounted in the table.

Freehanding that seems like a great way to lose digits.