WIRELESS SPEAKER BOXWITH CORNER DOWELS

BUILD IT WITHROCKLER PROJECT PLAN

BUILD QUESTIONS? Go to www.rockler.com or call 800-279-4441

30688 1/2" x 3" x 24"Padauk

65069 1/4" x 3" x 24"Maple

20719 1/4" x 36" Birch Dowel Rod

55985 1-7/8" Forstner Bit

All items subject to changes in availability.

Stock # Item59517 Corner Key Doweling Jig63837 1/4" Extended Length

Drill Bit57033 Wireless Speaker Kit

Stock # Item

WIRELESS SPEAKER BOX WITH CORNER DOWELS

MATERIAL LISTT x W x L

1 Sides (4) 1/2" x 3" x 3-1/2"2 Front and Back (2) 1/4" x 3" x 3"3 Dowels (8) 1/4" x 1-1/2"

1. ROUT THE FRONT AND BACK GROOVES IN THE SIDES

Set up the router table with a 1/4" straight bit. Rout two 1/4" deep x 1/4" wide grooves on the inside face of the stock that will make the sides. Locate the gooves a 1/4" from the edges. These grooves will capture the front and back pieces.

Attach a sacrificial fence to the table saw miter gauge and set the miter gauge square to the the blade. Tilt the table aw blade to 45 degrees. On a left-tilting blade saw (as seen in this photo). Place the piece of wood that will make the sides with the grooves facing up. Cut the end of the piece off to make the first mitered end.

2A. BEVEL CUT THE FIRST END OF THE SIDES

Clamp a stand off block to the fence, locating the block in front of the blade. Position the fence to cut a 3-1/2" long side piece when measuring the long side.

Drill 1-7/8" holes through the center of the front and back faces. Use a sharp forstner bit. Hold the pieces secure using a screw clamp.

3. DRILL SPEAKER HOLES IN FRONT AND BACK FACES

2B. BEVEL CUT THE SIDES TO LENGTH

4. ASSEMBLE THE SPEAKER BOX

Place sides on a piece of painters tape with the corner miters touching. Apply glue to the miters (top left photo). Next, place the front and back faces in the first side and carefully roll the box together (bottom left photo). Pull the tape tight to hold the corners together. Then clamp the box with band clamps (right photo).

Draw dowel alignment lines on each side of the box. Locate the lines 3/4" from the front and back edges of the box.

5. MARK THE CORNER DOWELS LOCATIONS

6. TURN HANDLE BLANK TO SHAPE

Install the 1/4" drill guide bushing in the corner key doweling jig. Adjust the drilling plate to the 1/2" thickness setting. Line up the jig with one of the alignment lines and clamp the jig to the box. Drill a 1/4" diameter dowel hole through the corner of the box. Then repeat the process for all eight corner holes.

Apply a small amount of glue in the corner dowel hole. Then twist the dowel through the hole until a small amount of the dowel pokes through the other side.

7. INSTALL THE DOWELS

8. TRIM THE DOWELS

Trim the dowels nearly flush with the sides. Then sand the remaining exposed dowel end smooth with the sides. Spray or wipe a finish on the all sides of the box.

Feed the wires from the speaker pod through the front of the box and connect them to the control pod on the back side of the speaker. After connecting the wires, press the pods into the front and back face holes.

9. INSTALL THE SPEAKER