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Project Plan

1.I will start out by cutting the back and front of the speaker out of MDF using the band saw

2.To perfect the shape I will use sand paper to smooth the curves and get them the same on the front and back pieces

3.After getting the correct shape I will use a pillar drill with a hole saw the correct size of my speaker driver and drill four holes two bigger than the other two. Once drilled out I will sand the inside of the holes to make the endless smooth

4.Using MDF I will mark out the size of the two sides then using a band saw cut them out

5.To cut the inside of the side out I will drill a hole then place the blade of the hegner saw inside then cut out along the markings, I will then repeat this for the other side sanding the edges down

6.To join the sides of the speaker to the front I will use a dowel joint by drilling two holes in the same place on the side of the front and back piece, using wooden dowel and PVA I will join the two together. Once the joint has dried I will use sandpaper to sand down the front and top of the joint to make it level.

7.I will fix the speaker drivers in place by firstly placing a mesh cloth overthrew hole and pulling it tight. I will then place the speaker on top of the cloth then screw it into the front of the speaker with screws. For the two smaller drivers I will have to use hot glue to fix it in place.

8.Once the drivers are in place I will mark out the flexi ply for the top part cutting it using the band saw and allowing it a little bigger than it is supposed to be. I will then place PVS glue along the edge of the base then place the flexi ply onto the speaker. To hold the flexi ply in place I will use small tacs and place them all along the side of the speaker.

9.Once dried in place I will sand the front of the flexi ply level with the front and side of the speaker with a clean edge.

10.While the back is still off I will fix the mesh in the sides of the panels where there is a gap. To secure it in place I will use hot glue.

11.Using a ruler and pencil I will measure the distance and the positioning of them buttons and mark them out. Using a hand drill I will then drill the 3 holes for the buttons into the flexi ply

12.I will then temporarily place the back on using tacs so I can mark out the shape for the underside flexi ply

13.Using a band saw I will then cut the shape out and fix it onto the speaker using PVA and tacs. Once dried I will then sand it down to give a clean edge onto the front and sides of the speaker

14.Using the metal lathe I will make some buttons out of solid aluminium making sure they are all the right height and can fit into the holes that have been drilled once they are the correct size I will glue them onto the button base.

15.Using hot glue I will glue the circuit board in place and secure all the wires in place to so there is no loose items that are able to rattle around.

16.Using the appropriate sized drill bit I will drill two holes in the back of the speaker for the power port and the AUX port. I will then place the ports over the holes and glue them in place.

17.I will now fix the back of the speaker. Just like the front I will use PVA and tacs to secure it in place.

18.Once the back has dried I will sand down all the edges of the speaker making sure that they are in line and level with the edges.

19.I will now use pre glued veneer to finish the speaker off. Using a ruler and scalpel I will be able to cut the veneer easily with clean lines. Then Using a iron I will glue the veneer in place by holding the veneer in place and pressing the iron over it. Using a fine sand paper i will sand the edges of the veneer to give a clean finish

20.Once all the veneer is in place I will varnish it with a clear varnish using a paintbrush. once the first coat has dried I will lightly sand it down with wet and dry paper smooth the varnish and then give it another coat of varnish and repeat this step

21.Once the varnish is finished and dried I will use tech soft to make the symbols of the up and down volume and power symbol. I will then get this cut out of black vinyl using the laser cutter

© 2013 Joe Peagam A2 Design Technology

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