Squaring Cuts to make before you start building a box. - Car Audio Classifieds!
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Old 07-25-2009, 09:48 AM
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Default Squaring Cuts to make before you start building a box.

When cutting from a 4ft X 8ft sheet of material, the first thing you need to know is that it is not square to begin with.

No matter what you cut it with, if you start with an un-square sheet, you will end up with un-square pieces.

You need to "Square it up" by marking square and trim cutting both ends based on one side. (trim off just enough to make it square)


Then make a square cut on the opposite long side. (this can be checked by measuring as well as using a drywall square)

These three squaring cuts should be your first priority when starting your cuts. This makes sure your material is as square as can be.
Think of it as a foundation. If the foundation isn't right, any thing you build on it will not be either. So square it up.
There is nothing worse than assembling your box and having it look like a holesaw just before you put the top on. {every piece taller at one end than the other}
[ok there might be something worse but I don't want to know. so keep it to yourself]

(It helps to plan the box having many panels the same length) (front, back, top, bottom... say.. 34")
(then you can make one long cut be at 34".. so your build takes the least number of cuts)

When I build a box, I predrill and countersink every screw and place them on 3" or 4" centers, then I glue and screw and seal every seam. 6" centers is ok for normal boxes. 3" is best if you are building a high pressure box.


Resource/reference picture:
$25 drywall square from lumberyard:

Attached Images
File Type: jpg unskinny box.JPG (36.6 KB, 158 views)

Last edited by iamsonic; 12-01-2011 at 11:48 PM. Reason: attached a picture of what will happen if you don't make squaring cuts.
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