First up, while it's still chilly outside, I cut the tolex to length. I'll need the back piece and the four pieces for the sides.
I then took the tolex pieces to the garage and coated them with contact cement. I then fixed the cleat issue and drilled holes for the handle & hold-downs on the cabinet. I then used wood putty to fill some of the hammer divots and parts where the router tore out the edges of the cab. It's not prefect but it works. Then I sanded everything.
Now for the fun part...applying the tolex.
Attaching the side pieces.
Working the corners.
Working the tolex into the back edges.
YAY! It's taking shape and actually starting to look like a Fender cabinet!
Yeah, I knew this was going to happen. The back panel doesn't fit even without being covered. Since I don't own a table saw, I'll have to sand.
Whew. Hours later (and a saw dust coated garage), I finally have a test fit with the back piece of tolex. Now to fill and re-drill the holes, coat with contact cement and apply the tolex.
Yup. The front baffle is the same. Looks like a trip to Home Depot is in order to get more sand paper.
It's coming right along...
It slides in, now to adjust for grill cloth.
Not perfect but it'll do. Now to clean everything up and get ready to install the tone ring & grill cloth.
Well this sucks. I measured and drilled the tie-down holes as per the documents but my showman head extends over the holes. Damn. I pulled out the hold-downs and filled with wood putty. Actually, the wood putty doesn't work too good. I'll get a 1/2" dowel rod and cut and glue into the holes. I think I'll just not put them in. Honestly, I probably not use them anyway. The brackets on the head add more weight to an already heavy head. Lesson learned. Don't always trust everything you read.
(Yes, the handle is offset. Not sure if Fender did it this was but it makes carrying this heavy cabinet a tiny bit easier)
Now to finish up the front baffle.
Here's the finished back without screws.
Applying epoxy to the speaker bolts on the ring. These babies are not coming out!
Touching up the screw heads. I need to do a better job of wiping off the sawdust.
Yes, the JBL looks rough. It actually needs a recone. I'm just using it to hold the screws in place while I epoxy them down. If some epoxy or paint gets on the speaker, it's ok. It's getting reconed anyway.
Next steps:
Put the felt strips around the speaker hole.
Mount the tone-ring to the baffle.
Attach the grill cloth.
Add the corners and feet.
Attach the front and back baffles.
Attach the jack and wire the speakers.
Updated 02/20/16
