Finishing the Mains

• The sides of the boxes were stiffened with a second layer of MDF this was 1/2" thick. The speakers are masked of to protect form adhesive spills.
• The pieces of laminate were cut to size on a table saw.
• Center marking the laminate and cabinet to ensure proper alignment.
• Rolling on the first coat of 3M "FastBond5".
• First coat drying.
• 3M "FastBond5" kills brain cells by the thousands. Disposable roller tray.
• Aligning the laminate.
• Rubbing down the laminate. Some people use a "J" roller for this. On small jobs Thomas prefers to do it by hand.
• First side down (see the green strip) Second side dusted and ready for adhesive.
• Me using the monster Hitachi. Routing both the 1/2" MDF and high pressure laminate at the same time.
• Same as previous, but a better view of my butt!
• Prep filing the top flat before applying adhesive.
• All sides completed.
• Applying adhesive to a top piece of laminate.
• Close-up of protective masking for front baffle.
• Close-up of the masking for the rear of the speaker, ports and input plates are covered.
• Top laminate adhesive drying. My butt was in a previous picture, so apparently it was time for a shot of Thomas' posterior.
• Setting the top laminate.
• Setting the top laminate again.
• Top laminate before routing.
• Cabinets ready for trim routing of the top laminates.
• Checking the laminate trim bit for proper depth of cut.
• Completed trimming of top laminates.
• Some people use 7 degree or 45 degree router bits to "ease" the edges of the laminate. Thomas prefers doing this by hand with a fine file.
• Laminating completed.
• Removing the protective masking from the speakers.
• Completed. Sides cleaned with acetone, then given a coat of Armor-All.

Adding Spikes and Sealing the Drivers

• The spike kit parts, for the bottom of each speaker (minus the center channel).
• Many of the drill bits used to drill the holes.
• The drilling jig being used.
• The threaded inserts that hold the spikes are inserted with a "T" handled Allan wrench.
• A close up of one of the inserts and the Allan wrench.
• A picture of the back of the speaker after the paint was applied.
• The front baffles with drivers cutouts sealed with masking tape to prevent router dust from getting in the hole when trimming the laminate.
• The laminate being applied to front baffles.
• Drilling the driver mounting holes to hold the tweeter in the front baffle.
• Easing the sharp edges of the laminate with a hand file.
• Soldering on the tweeter wires (note the stiffening and damping materials added to the back of the tweeter subenclosure).
• Applying rope caulk to seal the woofers.
• A close up shot of the stiffening and damping materials added to the back of the tweeter.
• A close up of one of the spikes installed.
• Removing the excess rope caulk around the edges of the speaker.
• A completed speaker.
• MTM height comparison with a Whisper.
• Here's the completed product for the center.
• Another shot of the center, they look damn near professional now, especially for speakers that started out as nothing more than prototypes.
• Here's a close up of the drivers/tweeter on the center channel.

Movies

• Thomas rolling a coat of 3M "FastBond5".
• Me routing off the excess edges.
• Thomas filing down the sides of the speakers to smooth them out.

See my home theater page for more pictures...