(Can you say: "mini statements.") JonFo, I think I hear a business venture calling.
you build, I buy. Come on let's go I'm ready...
Ah! We have a hidden treasure here in the ML Club!
Rough estimate, what would a cabinet made of 1" MDF, 9"x48"x24", with 2 horizontal braces (1"x7"x22") one up 16" from the bottom, one up 32" (with the center routed out), and then 6 7" diameter holes evenly spaced, cut into the front (with a 6" cutout in the middle, and then a 1" edge that's only routed out 1/8"...so the drivers can mount flush)...cost? Unfinished, Finished with a basic veneer, Finished with a fancy veneer (call it rotary cut bubinga, for grins)
Also, how much time do you think that would take you (in work hours)? (for the cabinent, and for any finishing?)
Your material cost is relatively low. The 1" MDF is about $50 a sheet. You need just over 1 sheet per enclosure if my figuring is correct.
I would suggest using an MDF brand name of Ultralite or Trupan. They are made with wood fiber just like other MDF. It is a little bit lighter and it uses a wax binder as opposed to Ureaformaldehyde glue. With formaldehyde glue even if you seal all surfaces my experience is it will still out gas vapors through the finish. People who are sensitive to this will have burning eyes, nose and throat.
If one design is settled on making a few jigs is no big deal. I have always hated production work so I would only cut pieces for maybe 4-6 enclosures at one time. I think Risabit's time estimate is probably pretty good. The fabrication time would be almost split between construction and veneering. This also depends on the veneer. Some highly figured veneers are much more difficult to seam together and glue down.
Finishing can be a whole different thing depending on what type of finish one wants. There is a big difference from a standard furniture finish with grain showing and a filled piano finish that is mirror like.
You can spend a few hours on something simple just to have a speck of whatever drop in your lacquer and you have a repair that might take almost as long as the entire finishing job should have.
There are many beautiful veneers available. I buy most of mine from Certainly Wood http://www.certainlywood.com/woodmenu.asp Take a look at what they offer. For each box you will need 20 sq. ft. not including the back. But depending on the veneer you will need to buy 50-100% extra for trimming and matching a nice pattern.
Quarter cut Bubinga is about $2 a foot. You might spend up to $80 per enclosure. If you want an exact grain match on all sides you would need to buy enough consecutive pieces out of the veneer flitch to be able to cut from the same end to book-match the width you need. In that case you might spend $200+ for veneer. Your cost would come down if someone else wanted the same veneer and you could split the cost and use pieces from further down the veneer.
It might be good to have people in different areas willing to build as packaging and shipping will be another concern. Each box will be about 80+ pounds I would think.
I would still be willing to build some basic boxes for people once I am up and running again with my shop. At least until the volume gets out of hand. But there will obviously be other costs involved depending on what someone wanted.
Another possibility for DIYer is there are a number of self adhesive backed veneers available you can stick down and trim with a razor blade and sand the edge smooth for those who don't have much experience with this type of projects. For finishing there are some very good brush able finishes you can apply and rub out for a very nice result. It just depends on how much one wants to get involved.
Lets see where we go from here.
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