This is how the cutouts were made for the M-T-M sub-enclosure. The baffle is indexed to the center of the saw blade. With the blade lowered the saw is started and the blade is slowly raised. This is quite dangerous so be forewarned!

This is just another view of the process. Note, the blade guards have been lifted for purposes of the picture. They were in place during the cutting.

This is the test fit of the newly cut back baffle. The spacers between the front and rear baffles are 1 1/8" Birch dowels. The brown "dot" in each corner are where the screws that attach the baffle, to the dowels have been counter sunk and the remaining holes filled with epoxy. Next, the laminate is applied to this side of the baffle

This is just another view of the operation attaching the dowel spacers to the rear baffle.

Here the laminate has been applied and trimmed. The "beading" edge detail has been routed. Now plastic wedges are being used to align the front and rear baffles prior to final attaching

This is a view of the process of attaching the rear baffle to the sub-enclosure. 1/4 round wood molding is used as a "gusset". The non-exposed sides are coated with epoxy then it is nailed in place. The nails are toe-nailed in at angles to catch both the baffle and sub-enclosure.

Now the front baffle is being attached to the dowel spacers. The screws can be seen prior to their being set. After the counter sunk holes are filled with epoxy and sanded smooth the baffle is ready for the laminate.

Here the laminate has been applied to the front of the front baffle. It has been trimmed ,and now the cut-outs are being made for the drivers. The edge is covered with duct tape to protect is from the router bearing.

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