Bass Amp Enclosure Questions

[N4860]

Hey everyone, first off, please move the thread if this is in the wrong place.

I am building a basic enclosure for a bass amp. Basically just a rectangle box with a 2U rack rail built inside to fit my amp. I will be putting tolex around the enclosure to match my cabs but I just have a few questions:

1. What would you recommend for the wood in terms of thickness and type? 1/2" plywood of some type? I'm probably just going to pick it up from Home Depot so something readily available is ideal.

2. What is the best method for rounding the outside corners of the enclosure to match something like a Mesa Boogie Subway series cab (as seen below)?

I do not have access to a router so what would be a good alternative? Wood file?

3. Lastly, what is the recommended product for applying the tolex? I watched a couple of videos and I saw in the comments people saying that certain glues will melt the tolex. I'd prefer to avoid that happening.

Thanks in advance for any help!

 

[Gilmourisgod]

1/2" plywood should be fine, use a roundover bit in a router to ease the edges. Ive done Tolex with Super 77 spray adhesive, or you could use contact cement. The 77 didnt have any "melting" effect on the Tolex in my case. The spray stuff is easier IMO. Don't Wing it, spend some time drawing a plan before you cut anything.

 

[N4860]

1/2" plywood should be fine, use a roundover bit in a router to ease the edges. Ive done Tolex with Super 77 spray adhesive, or you could use contact cement. The 77 didnt have any "melting" effect on the Tolex in my case. The spray stuff is easier IMO. Don't Wing it, spend some time drawing a plan before you cut anything.

Thank you, I'll look into the Super 77. I will certainly be putting a blueprint together once I get my rack components.

I don't have access or experience using a router. Do you think using files and rasps is a bad idea?

 

[Gilmourisgod]

You could file it by hand, just take your time and nibble away at it. Draw a circle with a 3/4" radius on some card stock, cut it in quarter and use it as a template to gauge your progress. The Super 77 is available in most hardware stores, Gorilla and Elmers make similar spray adhesive. Make sure you have the Tolex lined up right before you press it on, that 77 grabs Quick. Watch a few YT videos on how to Tolex a box, some technique involved.

 

[Beej]

I also use 3M Super 77, Canadian Tire carries it in the auto paint section. You can certainly do it with a file and rasp, but it's unlikely to be as perfectly clean and consistent as with a router. Not a major issue, but your eye will tend to see it on the textured surface of tolex. It's unfortunately more unforgiving than it appears.

 

[Slidlow]

I do mine with water based contact cement. I brush it on. Less noxious and I had problems with the spray ones letting go and edges peeling back.

 

[N4860]

Yes, I did see the Super 77 is available and in stock at few nearby stores so I'll be picking that up.

I might just go ahead and pick up a cheap router. For the roundover bit, if I am using 1/2" plywood, should I use a 1/2" roundover bit?

 

[ctmullins]

I might just go ahead and pick up a cheap router.

If you’ve never handled a router before, please be careful. Watch some videos, read the power tools sticky in this forum. Always wear safety goggles. Clear your mind and focus only on the routing. Secure the workpiece before beginning. Use good lighting.

For a job like this, one of the small trim routers is more than sufficient. I can’t recommend buying a “cheap” router, as cheap tools aren’t built as well as reputable name brand tools, which could result in vibration, erratic cutting, and a less satisfying experience, if not perhaps actual injury. A Bosch Colt is a quality tool, and not particularly expensive.

 

[T_Bone_TL]

I did something vaguely similar, no tolex.

TNT130 Head Case

It did get a roundover but I guess I never updated the thread. It's been less of a priority since all the actual gigs have been unamplified upright...

I used 1/2 or 5/8 actual wood for the sides, and 1/8" masonite for the bottom, two strips of real wood front and back on top. 1/2" ply top and bottom is "rugged" but also trends "heavy" and arguably considerably heavier than is needed if your gear is not being thrown about by uncaring jerks. If the roundover look is important to your conception, you can make an edge frame from 1x1 and inlet 1/8" ply (underlayment birch has been a good deal in the past - not sure how the covid-market has affected it relative to other options) or hardboard for the large area coverage.

 

[N4860]

If you’ve never handled a router before, please be careful. Watch some videos, read the power tools sticky in this forum. Always wear safety goggles. Clear your mind and focus only on the routing. Secure the workpiece before beginning. Use good lighting.

For a job like this, one of the small trim routers is more than sufficient. I can’t recommend buying a “cheap” router, as cheap tools aren’t built as well as reputable name brand tools, which could result in vibration, erratic cutting, and a less satisfying experience, if not perhaps actual injury. A Bosch Colt is a quality tool, and not particularly expensive.

That Bosch Colt is actually the one I was looking at. If do go this route (pun), I'll certainly be watching some videos and practincing with some test pieces first.

 

[N4860]

I did something vaguely similar, no tolex.

TNT130 Head Case

It did get a roundover but I guess I never updated the thread. It's been less of a priority since all the actual gigs have been unamplified upright...

I used 1/2 or 5/8 actual wood for the sides, and 1/8" masonite for the bottom, two strips of real wood front and back on top. 1/2" ply top and bottom is "rugged" but also trends "heavy" and arguably considerably heavier than is needed if your gear is not being thrown about by uncaring jerks. If the roundover look is important to your conception, you can make an edge frame from 1x1 and inlet 1/8" ply (underlayment birch has been a good deal in the past - not sure how the covid-market has affected it relative to other options) or hardboard for the large area coverage.

Thanks! I'm going to be checking out a home depot today to see what sort of wood I want to use and to get an idea of how heavy it is. Fortunately the amp is pretty light, only a few lbs. and pretty small so I don't think the case will get too heavy.

 

[Slidlow]

Check out their 3/4" pine. Fine for a cabinet and light. They also have the laminated wide sections for shelving.

 

[Zoffy]

Another option to consider instead of tolex is DuraTex. It's a roll-on paint that dries hard and leaves a rough grainy pattern similar to tolex. I used it on an Ampeg SVT 410 restoration and had really nice results; I'd use it again for sure. It's comparable in price to tolex when you factor in the cost of the tolex adhesive. As far as rounding the corners without a router, try an electric sander moving slowly from the center edge outwards. Good luck!

 

[N4860]

Another option to consider instead of tolex is DuraTex. It's a roll-on paint that dries hard and leaves a rough grainy pattern similar to tolex. I used it on an Ampeg SVT 410 restoration and had really nice results; I'd use it again for sure. It's comparable in price to tolex when you factor in the cost of the tolex adhesive. As far as rounding the corners without a router, try an electric sander moving slowly from the center edge outwards. Good luck!

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Thank you for the advice! I am doing the tolex to match the finish of the cabs since the cabs are a coloured tolex finish this is going to be the best way to match the enclosure to the cabs. I was, fortunately, able to find the same tolex finish at a local store and picked some up today. I think I'm going to just get a router and learn how to use it. It would be handy to have for other wood working projects anyways. Besides, my wife has been trying to get me to give her ideas for Christmas presents so now I can tell her to get me a router.

 

[Zoffy]

Thank you for the advice! I am doing the tolex to match the finish of the cabs since the cabs are a coloured tolex finish this is going to be the best way to match the enclosure to the cabs. I was, fortunately, able to find the same tolex finish at a local store and picked some up today. I think I'm going to just get a router and learn how to use it. It would be handy to have for other wood working projects anyways. Besides, my wife has been trying to get me to give her ideas for Christmas presents so now I can tell her to get me a router.

No problem; hope the project turns out well!

Don't forget to ask your wife for bits to go with the router; they make great stocking stuffers (Come to think of it, I may ask my wife for router bits for Christmas...hmmm).