Yesterday I glued and clamped the patches behind the side sound ports. Here is what a patch looks like.
Then it was time to cut the hole. That is done with a drill bit in the Dremel, simply making a series of holes around the drawn oval. Then the hole is perfected using a disc sander in the Dremel. You go very slow wanting to get a perfect fit.
After many fittings, the ring finally slips tightly into the hole.
where it is glued in with superglue injected from the inside.
And after a little whittling and sanding we have a nice looking and effective sound port.
And so now we have two generations, two about finished for Ree and Stephen and two that will be boxed tomorrow for Cazzie and Michael.
