General box-building questions

[Birdie2000]

Hey all, just had a few questions on box building in general (not for a f-body). Any help would be greatly appreciated.
1.) When making a wedge style box, what do I do so that the screws are flush with the surface of the wood so that they don't create any bumps when covering the box?
2.) What are the best type of screws to use on a box?
3.) What tool do you use to cut the circles for mounting rings such as those used in fiberglass pods? I want the rings to be as close to a perfect circle as possible.
4.) When mounting multiple subs in a sealed enclosure, is it best to divide the box so that each sub has it's own small sealed box, or just make a box that meets the total airspace requirements for all of the subs with no divisions?

[spunger]

Hey there, I see you have some box questions so I will try to help.

1. I believe you can countersink the screws if you do not want them to stick up. I think it is a special drill bit you use on your drill. Nothing very hard.

2. I have no idea, I know I had some around but I can not for the life of me think of their size or name. I know they were drywall screws though.

3. There are jigs that people make for their routers to cut the circles. I myself use my speaker as a template and just use a jigsaw. Works ok if you take your time.

4. All the boxes that I have seen have seperate chambers. I think it is for a few reasons. By making seperate chambers if a sub goes out you can tell, rather if it is just one big box you can't tell too easily. Seperate sealed chambers also have less cancelation of soundwaves. Overall if you got the extra room I would say go with the sealed space per sub.

Hope that helped with some of your questions,
Chris

[megabass]

Pretty much what spunger said. If you don't have a countersink bit, you can use a regular bit that is close to the same size as the head of the screw and drill into the baffle some. I usually sink the screws down real good and bondo over top and sand it down so you can't tell they are there. The vinyl is real picky about showing any imperfections underneath. I use 1-1/4" wood screws. Drywall screws will work as well. I use that length because it won't go thru two pieces of 3/4" material.

I made a circle cutting jig for my router. You can buy them too. This works way better than a jugsaw because the holes are a perfect circle when you're finished.

You should always separate the chambers if possible.

[DrMilhouse]

1. I second mega on that. I actually don't use a "counter sink bit" I use a bigger drill bit and just drill out a shallow area for the screw to go into. You can actually make it a little two deep and then bondo over it. That's particularly helpful if you're using vinyl because it's not forgiving at all about little stuff under what you apply it to.

2. second the other guys on this too. I usually always use Drywall screws.

3. We can't all afford a router and a jig and gas for our cars. I used a rotozip with a cool circle cutter. It works great. Don't make that your first circle cut. Practice on something else first cause you're gonna mess up the first one.

4. [voice of experience]
always separate the chambers. no two speakers fire at the same time and you'll mess up the voice coil of one (if your lucky) or all of the speakers that are in the same shared sub enclosure.
[/voice of experience]