Couple of Speaker Builder Questions

[Ben Esparza]

Question 1: What size round-over router bit do you use to match the round-over radius of the plastic stacking corners?

Question 2: What do you use in order to get a seal between the speaker flange and the Duratex finish?

[DukeLeJeune]

I use a 3/8" roundover because I'm building with 1/2" plywood; if I was using thicker plywood, I'd probably use a 1/2" roundover, which I think would be a better match for the plastic stacking corners.

I use a smooth roller or brush for the layers of Duratex that the speaker will sit on top of, and then I keep the Duratex off of that area for the rough-roller top coat layers. The woofers I use have a gasket on the back, which helps. Otherwise, I'd make a gasket out of gasket tape from Parts Express.