Some more progress. Came out of hospital this morning and told to rest, so naturally my time has since been spent in the workshop where the speaker side panels were busy "cooking" in the DIY laminating machine. This consists of a table top with a hinged alloy frame and inlets for vacuum pipes connected to an electrical motor and vacuum pump. It generates 14lbs/sqr inch pressure on whatever former is placed into it (there's a tough plastic cover attached to the hinged frame which pulls down over the former). Once the motor's started, the plastic pulls down evenly across whatever piece of work you want to put in there, and holds it for gluing/forming for as long as needed. Each of these panels was in for around 4 to 6 hours:


Machine in action with one of my speaker side panels being formed from 6nr 4mm Birch ply sheets glued with PVA:



Vacuum pump turned off and former lid removed:



One of the panel edges had rippled slightly but not as bad as it looks since the panel width is oversized to allow for this edge rippling which can sometimes occur. It'll be trimmed up and will be fine:



One of the laminated panels at rest for a day or so after gluing up to allow for any further movement before final trimming:



Each of these sides weighs approximately 15kg! You can imagine what each speaker will weigh with two of these, the front and rear panels (front panel is 30mm thick!), bracing, damping and drivers. It will be a two man lift per speaker for sure.