hi all-- I'm building a set of 5 speaker cabinets for a home theater and i'd like some construction advice, and some advice on what type of finish to apply. The speakers are about 2.5' ft tall by 10" wide by 1' deep. Cabinet material is (not surprisingly) 3/4" MDF. In the past, I've used butt joints. While this method worked fine, this time around I plan on doing all the joints as 3/4 dovetail; i chose this method because i wanted the maximum amount of surface area for gluing, and I figure as the MDF ages, this will provide the most stability with regard to expansion/contraction. I'll also countersink the drivers into the baffle with rabbets; I plan on using a circle-cutting jig attached to my plunge router to cut the rabbets and holes. Are there any other construction tips folks can offer regarding speaker cabinet construction? now, With regard to the finish. I have had problems in the past getting an even finish on the MDF endgrain, and with the dovetail joinery, i will have an odd endgrain pattern. To combat this on the baffle, I was going to rout out 3/4"x1/8" around the outer edge of the baffle and inlay some cherry in that channel. However, I don't want to rout the endges of the whole cabinet on every surface. How does one finish MDF to get a uniform look? I wanted to do a piano black gloss finish for the whle cabinet, but after reading some posts this seems impractical unless I send it someplace. Any idea where I could take the cabinets/what this would cost for 5 speakers (i am in boston, MA)? What alternative finishes are there that are more easily applied? thanks for your thoughts. Rich
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20 years ago