I'll gladly spend some time on the phone with you if needed, I just helped someone do theirs and he had no issues.
Basically we reommend building them on their side ( full wing down first) Recommend using Titebond Extend so you have some extra working time.
Do some dry runs first to get a feel for how you are going to assemble them.
I recommend:
Lay the first wing down, dado's up.
Add a nice bead of glue to each dado in the wing except for the very top brace.
Put a brace in each Dado.
Apply liberal amount of glue to the 10 degree rabbet and each dado on rear of wing
Fit baffle over front edge of wing on bench, easiest if overhanging the bench slightly. You can use a few small 6.5" clamps from roundover of woofer cutouts to outer face of wing to hold it in position. Make sure all the braces fit into the dado's on rear of baffle. There maybe a bit of clearence on some when aligned with rear edge... have to leave some wiggle room due to material expansion/contraction in different climates.
Add glue to remaining 10 degree rabbet on baffle (facing up at you). Add glue to all dado's on open wing except very top .
positon 2nd wing over exposed bracing until it drops into position..
Now, quickly install the 6 dowels in bottom of wings and (Without Glue) attach the base (fits over dowels) and then secure with 6 screws..
Stand the speaker up and begin clamping it all up.
We used a stack of 6.5" clamps from inside driver cutouts to outer edge of wing to keep the wings up tight against side of baffle. We cut a piece of scrap wood just wide enough to reach across the rear of the cabinet, so it just catches the inside edge of both wings and clamped from there to front baffle to pull the wings forward into the baffle. We did this on the upper M165 section and the lower M165 section.
We also added a couple of band clamps around the upper and lower sections.
Using the base as a jig keeps the wings aligned and makes it much easier. After the cabinet sets up in clamps, you can remove the base and reinstall with glue and screws if desired. The top brace ( wedge with single cutout,, is easy to fit after initial glue up.
You do not need to go crazy with the glue, you don't want it all squeezing out and running all over the place.
It is a little tricky but as mentioned, doing some dry runs really helps simplify the actual glue up process.
I can't emphasize enough, go easy on the glue. Too much glue is only going to cause you grief, it will cause a ton of swelling and making fitting/adjusting etc really touigh.
jay
