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45. Remove the clamps from the port, set the cabinet on its back, and check the front for square
again. If the cabinet is not square, clamp the baffle tightly into the acute corner again. This will
pull the whole box perfectly square. Leave the whole thing alone for at least four hours!
46. After the glue is completely cured, remove the baffle and inspect the joints. If any joints are
poorly mated (for example, the Ports stick out of the cabinet, or the Front is not flush with the
cabinet), grind them flush with 60 or 80 grit sandpaper.
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Edge Detail: If you want to apply a router detail, now's the time. There's only room for a small
chamfer or roundover. (If you don't want to use a router, you can achieve a similar look simply
with a lot of hand-sanding.) We use a 3/16" roundover bit with a bearing at the bottom.
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NOTE: As you route each edge, be careful to orient the router so that you do not run the bearing
across the screw heads. This will result in blemishes that can ruin the cabinet!
Round over all the outside edges except the four back edges. Detailing the top front edge is
optional and up to you. We like to run the router all along that edge as well,
sharp little inside corners to be dressed up with some hand sanding.
DANGER!
Routers are dangerous, tricky machines that can do you serious harm if misused. If
you are unfamiliar with routers, get a friend to help you!
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201,202
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