We are starting 4 new Tuba 60’s. This time I plan to document what we do. Here goes.
A special thank you to B.Shyne for really going to town. Excellent work. Much appreciated. =)
http://www.palsearthsource.com
First off, where to get the wood? I love PALS (Plywood And Lumber Supply). They are environmental and know their products. They are exactly the type of company that Home Depot runs out of business and then everyone is sad when they are gone. These guys are great and they have exactly the wood we require at the right price. Helps that it makes the world a better place when we buy from them.
4 tubas will take:
(10) 4×8 sheets of 1/2 birch plywood
62.50 each
$650 total
http://www.fullcompass.com/prod/230063-Eminence-Speaker-LAB-12C
Full Compass is great. Good prices. No nonsense. Free shipping. No tax.
4 Tubas will take:
(4) Eminence Lab 12c
$175 each
$710 total
Odds and Ends
We may decide to screw the final face down. [We glued the first 4 on but now they are impossible to service.] We will use 8 rolls of small weather stripping.
http://www.homedepot.com/p/MD-Building-Products-1-2-in-x-17-ft-Weatherstrip-Tape-02279/100353461
Each tuba needs eight (8) Tee-Nuts for the speaker baffle (16 packs total).
We use the Kreg tool for the braces.
We use 1” and 1 1/4” drywall screws.
We will use two (2) 28 oz. Loctite PL Premium adhesive.
Cut Sheet
Cut #1
60×48″
This creates a scrap piece that is 36×48. Place that to the side.
Cut #2
60×30″
This creates a second scrap that is 18×60.
Cut #3
We use these two scrap pieces to cut the remaining “width” pieces. Our width is 14 1/8”. We then cut all scraps to the current width.
14 1/8×60
14 1/8×36 (3 times)
The width pieces are listed below ordered by both length and part number.
Note: Each Tuba requires just under 2 and a half sheets of premium plywood. If we make the bracing out of different material, we can use as little as 2 and 1/4 sheets of premium plywood to make a single Tuba.
Note: We made these cuts for all 4 Tubas at the same time. We never moved the table saw rail to unsure the widths match.
We chose to cut the longest pieces first as the smaller ones can be cut from their scraps.
All cuts are rough. Almost all pieces will be cut again when fit into place. For this reason, err on the side of making the pieces longer, not shorter.
Ordered by length
(12) 59 ¾
(8) 51
(2) 42
(6) 35
(3) 34 ½
(10) 29 ¾
(7) 20 ¼
(1) 13 ½
(4) 8
(13) 8
(5) 7 ¼
(11) 6 ½
(9) 5 ½
Ordered by part number
(1) 13 ½
(2) 42
(3) 34 ½
(4) 8
(5) 7 ¼
(6) 35
(7) 20 ¼
(8) 51
(9) 5 ½
(10) 29 ¾
(11) 6 ½
(12) 59 ¾
(13) 8
