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Starting a new build of a set of Belles.

 

Material is 24mm baltic birch ply for the doghouse & 18mm baltic birch ply for the rest of the cabinet. The sides & back will have two layers of 18mm ply. 

Here is the new table saw which should do the job. 

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First up is a full scale drawing of the dog house. From there I will work outwards towards the external sides of the cabinet. 

 

The dimensions were altered to account for the thicker ply material & to keep the internal dimensions of the dog house the same as the original design. 

 

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Next is to transfer all the dimensions to the baffle panel & cut the slot, which I did with a router. 

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Then I made a jig to cut the steep angle on the ramps. If I did this again I would make this a bit differently as with this jig I couldn't cut through the full width of the material & had to do two cuts. Still came out reasonably OK though. 

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Cut the angles for the sides of the dog house & everything was held in place with a few nail gun nails & then glued & screws together. 

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Next I will veneer the dog house as it's much easier to get to before the cabinet is assembled. 

 

The veneer is Silky Oak & will be finished with a clear lacquer. 

 

Going to take a break for a while now.

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Just a dry fit for one of the cabs. All seems to go together OK.

 

Need to complete the other cab & then dismantle & start veneering. 

 

Will veneer the doghouse, the inside of the bottom panel & the inside of the side panels. 

 

Then fit the backs & the extra layers for the sides & back. 

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Has anyone done plans for using a 8 inch or 10 inch woofer for these?


Sent from my iPhone using Tapatalk

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I love a good build thread. Thanks for sharing.

Sent from my SM-G986U using Tapatalk

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THIS is an amazing build , congrats ,  this might just be the most solid  BB Belle I have ever seen  ,

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Completed the rear panels today, complete with splitters. 

Just used some scrap material for the splitters & cut to size on the table saw. 

 

Also made a template for the veneer to go on the inside of the cabinets......at the bottom of the cabinet between the sides & the dog house. The template is sitting on the top of the cabs.... it fits really well.  I removed the bottom of the cabinets ......placed the cardboard underneath & traced out the shape.

 

It's going to be tricky to adhere this, as the contact cement only gives you one go.  

 

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Waiting on some screws to arrive before I can continue with the bass bin, so started on the mid horns. 

 

Will do these a few segments at a time.....here's the first five segments. 

 

These are glued & screwed together. Dave provides dowel pins to key them together in the correct position, so you can't really go wrong. 

Bought a Die Grinder to get the rough sections off first & then hand sand with varying levels of sandpaper.

 

The die grinder makes light work of this job & you can easily position it to remove even small amounts of material. I wish I had this when I built my last two sets!

 

Screws arrived today, so will get back to the bass bins on Wednesday.

 

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