Preliminary assembly

19mm MDF was used for this speaker and is much nicer to work than the chipboard of earlier models, although the router dust is apparently quite toxic meaning a respirator is needed

An internal frame was made from strips of MDF which allowed everything to be screwed together without glue at this stage. Once all the panels are finished, they are glued and screwed one at a time. After the glue dries, all internal seams are sealed with gap sealant to prevent any possible air leaks. The external seams and screw holes are filled with putty and then 3 coats of polyeurathane is applied