Got the sample finally, and have started the build. I love it when a plan comes together. Tony & Chaz must have spent a billion dollars boxing this up (sample went straight to VTT vs. my house), but UPS got a little damage in still (they don't like 60+ lb boxes, especially around xmas time).
First night I slapped some of it together (just placed, no glue/etc) to see how fitment and dimensions looked. Good. Real good:
So I started putting 'er together. Never go easy on the glue. Brads are just to help hold while glue is drying; they are unnecessary overall, but do help make life easier, right up until you have to cover the brad holes anyway.
She's going to be stout, no two ways about it. Material was spec'd as 20mm, actual was a hair over. It's not cheap, weak, or light.
Put a couple of dustcapped JBL's in raw just to see how it would look. I'm very happy, to me this is by far the most aesthetically pleasing design I've done to date. I love the deep recess driver look with the 12mm roundover. Has a super clean look IMO.
You could but a veneer on the sides and duratex the front/rear, but I'm just going to duratex the whole thing. It's easy, durable, non-toxic and reasonably priced -plus blends in to most decors. There will be MANY more of these to come so lets not get too crazy with finishing.
Finishing starts with filling brad holes, sanding, and fixing any issues (like the corners UPS wrecked but I fixed). Usually I use drywall compound but decided to use epoxy instead this time. I'm undecided; it's better for sure long term but what a PITA compared to slapping on some quick compound and being done. Some say the spackle will eventually pop out but I've never experienced that; I'm sure this epoxy is permanent though.
You can see one chunk missing on the top right(ish) part of this photo (lots of epoxy).
Some patience and all is forgotten. This is the bottom, and taken same angle showing the repaired damage; you can't see it.
This is with 2 coats of Duratex, I usually do ~4.
More to come soon including testing!
Chris