I used a friends jointer to get the edges perfect for the gluing up.
I bent the needle for getting into tight spots. It worked well:
Here is the water output with 90's and bulkhead installed. You want to install this before you install the 5" riser. So make sure it's tight! You only get one chance to do it.
Next i Installed the 5" inner riser. Because i had tilted baffle it sits on I needed to cut the bottom on an angle with my miter saw so it would stand straight and level:
Then i glued the top of the box on:
Next was the cup. This was the fun part where i learned how to make circles and flanges. I used my drill press like a milling machine. I set it to a high speed. I cut my acrylic sheet to the desired sizes,
drilled a small hole in the middle to fit a finish nail, nailed it to the press table and turned it into the 1/4" double fluted router bit. I used a 3/16" double fluted bit for the dado's to fit the 3/16" tubing in.
I cut the tubing with the table saw. I made a sled to roll the tube into the blade:
Tight fit!
I taped the flanges together and drilled the holes for the screws.
Then i tapped the flanges for the nylon screws:
finished.
