Firt I cut the fingerjoints with my router and really crappy Sears jig. Always an admirer of fellow cheapskate Rob DiStefano's DIY stuff, I wanted to do half-blind dovetail joints to cover up the gaps my crappy jig often leaves me... his always look so nice and nothing covers my mistakes like anything called "half-
blind".
As you can see, it only occurred to me to snap a few photos after I had cut, glued, and clamped the cab... but oh well.
I used a 3/4" router bit to cut "channels" into the inside walls an inch from the lip/edge. I then glued and clamped 2" wide, 3/4" pine trim into the channels to act as cleats.
I then rounded all edges of the entire cab with a round router bit.
Being the cheapskate I am, I decided to cut holes in the top to act as a handle so I wouldn't have to spend any dough on a strap handle.
I then rounded the edges with the router. Like the total dumbass I am, I forgot to cut the handle holes
before gluing it all together, to the underside of one handle I had to round by hand with a Dremel tool.
Next I cut a sheet of scrap plywood to size for the baffle. I took an old wooden paint stirrer and drill two holes in it, 5.5" from each other and used it as a compass to draw the 11" speaker hole. I then cut it with my router. Finally I painted the from of the baffle black.
