Laminating MDF Made Easy

Create an mdf template by stenciling shape upon mdf surface. Trim undesired material from mdf following stencil markings. Next (very important) manicure template edges before using as finishing template. Determine best/strongest place to screw template to mdf copy pieces (note- see photo, screw holes have future use). Place finished template upon mdf copy piece, screw down template and trace copy piece. Repeat this step as many times as needed for each end cap. Trim undesired material from these mdf pieces to within 1/8" of finished edge. A first starter piece will be needed for each end cap, screw template upon trimmed copy piece and flush cut. Repeat this step once for each end cap. Drill ¼" hole in all mdf copy pieces and starter pieces at point where screw hole appears. Apply glue to both sides of starter piece, insert a 12" piece of all thread through ¼" hole, then sandwich one copy piece to each side of starter piece. Put fender washers over all thread then tighten ¼" x 20 nuts on all threads. Use additional clamping if available or make a clamping jig with all thread and scrap wood. This will self align the pieces. Allow glue to dry at least an hour before removing clamps. Next, flush cut copy pieces to started piece. This time apply glue to copy pieces, insert a 12" piece of all thread through ¼" hole, then sandwich one copy piece to each side of first copy piece.. yada.. yada. Repeat as many times as needed until desired thickness is obtained.

The Finish

White High Gloss Lacquer Piano: All mdf surfaces were prepared before finishing. Yes some bondo was needed, not much though really. A 50%glue/ 50%water mixture was applied to all cut mdf edges using a brush. Allow surfaces to dry about an hour before applying another coat this time to all surfaces. The glue water mixture makes the mdf a rock hard surface. Now sand all surfaces using 320 grid sandpaper. Clean and wipe all surfaces before applying oil base primer. Sand primed surfaces with 320 grid sandpaper. Clean and wipe all surfaces, hang cabinet in clean location suitable for spraying lacquer. Lightly spray all surfaces with high gloss lacquer, allow an hour to dry. Take down speakers to clean terrycloth covered work surface. Sand all surfaces with 400 grid wet/dry sandpaper dipped in water. Paper towel dry, hand and repeat spray steps for 3 or 4 coats. Clear coat lacquer applied similarly to high gloss white lacquer except this step use 800 grid wet/dry. Repeat spray steps for 3 or for more times. Let speakers dry for 1-2 weeks before final assembly.

A decision was made not to install speaker binding post cups but they could have easily been installed on back baffle. There is a crossover access panel section below lower woofer. A channel runs along the bottom of speaker to crossover section for speaker wire connection.