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'Mass' Cab Production Method?

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DrewKaree:
Dunno if you have a router already, but if you are serious about doing this and want it to go easily, get yourself a larger horsepower router.  Something 2 HP or more should do fine, it's a sliding scale after that size as to what you want....more horses = more $$.  I've got a 3 Hp, but mine is work related...you may not want to spend that much after seeing how much they cost.  

Big shops that do repetitive stuff like this use pattern bits for a shaper.  If you think/want this to be a side income and think out your economy of scale, (sell enough cabs to pay for the shaper, that is) then the shaper is TRULY the way to go.  

If this will just be a lucrative hobby, forget I mentioned the shaper.  One look at the price will make you think your token run was cheap by comparison! (but DO invest in a larger HP router and high quality carbide tipped pattern bit....Freud or CMT make dynamite bits that last forever and a day and can be resharpened too)

ChadTower:
Just as a comment, I'm fairly new to cabs and definitely new to woodworking.

I LOVE THIS STUFF.    ;D

Santoro:
So the day after I cut my template, my router died after an hour of use.  I probably should have stopped when the router was 'hesitating' as I mentioned above.

It was a ~20 year old Sears Craftsman 2500 RPM model, I can't find a HP rating on it now - but will keep looking.

I can't go back now though because it was soooooo easy. I will be picking up a really powerful router next.

Don't try this with a cheapie router!!!!!

jcoleman:
Kelsey,

My question is...how did you make the template in the first place?  Did you make it by using an original cabinet as a template?  If not, how'd you get the curves so smooth?  I'd like to eventually reproduce a PGA Golf cabinet (kind of a Golden Tee ripoff) and there is a beautiful curve on it.  Doubt I'll be able to do that with a jigsaw.

Coleman

OSCAR:

--- Quote from: jcoleman on July 10, 2004, 02:43:27 pm ---Kelsey,

My question is...how did you make the template in the first place?  Did you make it by using an original cabinet as a template?  If not, how'd you get the curves so smooth?  I'd like to eventually reproduce a PGA Golf cabinet (kind of a Golden Tee ripoff) and there is a beautiful curve on it.  Doubt I'll be able to do that with a jigsaw.

Coleman

--- End quote ---

I actually did use a jigsaw to get the shape very close.  Then I spent some time with a belt sander to make it as perfect as I could.  I put some work into getting a very nice shape on the template, but keeping in mind that I would only have to do it once that way.

More details of how I made the template and the finished project are in this thread:
http://www.arcadecontrols.org/yabbse/index.php?board=10;action=display;threadid=21723

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