Double thickness front side?

[bbeljefe]

I made my cuts, and they don't line up too well. I dont have a belt sander, but would i use a dremel to even things up? lol

I wouldn't use a dremel tool as you can't get a good straight edge with it. And no belt sander either, for the same reason. To clean up ends, the best thing to use is a long block and some elbow grease.... And then once you have the box assembled, caulk the interior with Polyseamseal or painter's caulk. Some people use silicone but it doesn't stick well to wood, it's messy as hell and it smells like shite.

 

[Braindead]

I wouldn't use a dremel tool as you can't get a good straight edge with it. And no belt sander either, for the same reason. To clean up ends, the best thing to use is a long block and some elbow grease.... And then once you have the box assembled, caulk the interior with Polyseamseal or painter's caulk. Some people use silicone but it doesn't stick well to wood, it's messy as hell and it smells like shite.

Like a long block of sandpaper? And in some places it curves a good .25" away, maybe i should cut a few fresh pieces with the leftover mdf...

 

[bbeljefe]

Like a long block of sandpaper? And in some places it curves a good .25" away, maybe i should cut a few fresh pieces with the leftover mdf...

Yeah.... a piece of scrap about 2" by 10" wrapped with anything from 40 to 120 grit, depending on how much cutting you need to do is the best way to trim uneven cuts. The idea behind having a long block it so that it doesn't cut into one area and make a dip.

And if you've got cuts that are ¼" off, you should recut those panels. You need the cuts to be as tight as possible for both strength and sealing of the box.

Take a good straight board and a couple of clamps and make yourself a rip fence and you'll get good smooth cuts. I'm pretty sure there is a video tutorial on that in the enclosure section of this site but if not, search on youtube for "skill saw rip fence".