At times it is not enough to come close to the ideal of the perfect corner or the perfect curve. This is true as well for reflex ports which aside from their function for the sound usually are a nuisance. We wanted to show that they can be used as well as a design.
For the reflex ports to have an outlet the front does not nett the corners. You can cut the corners with a variety of methods, including and not limited to: jigsaw, router or hand circular saw. You should have a board or ruler to guide the machine of your preference at the right angle along the board so that you get a smooth and straight edge. The easiest way surely is a table mounted ciruclar saw with a parrallel and angular stop. The necessary set up is done in mere seconds and as quickly the edges are history. The boards that will create the canal were made in a similar way with the saw blade fixed at an angle.
Glue the lid and the front onto the side. After that glue the reflex port boards to the front, side and lid.
After the back board and the base glue in the midrange chamber. After the glue has cured, turn the casing onto the front and glue in the missing 2 boards for the canal.
Again some patience is in order, so that the glue can cure. After the glue has cured apply some more glue to the edges and close the box with that. Since we will not be able to have another look into the insides of the casing prior to sawing the holes one is well advised to make some markings like top, the position of the midrange chamber etc.Back to: Design - Long leg Forward to: Design - Side wall