Fixing Tweeter Screw Holes

Impious

Screwed up my notch for the terminal on the tweeter and cut about half way into the material behind a screw hole. I can't be the only person to have done this, so hoping to get some ideas on the best way to fix this.

My main concern is having enough material for the screw to bite and avoid leaks. My first idea was to fill the space with toothpicks slathered in plenty of glue. But willing to hear better ideas.

As an aside I blame HiVi for this. It costs $0 to adjust the terminals so they are offset from the screw holes which would make this 100% avoidable.

I also apparently have no idea how to post images on this forum.

(https://diy.midwestaudio.club/uploads/editor/ji/5qfnvg5f7eg8.jpg "")

Impious

There we go.

a4eaudio

@Impious said:
...My first idea was to fill the space with toothpicks slathered in plenty of glue. But willing to hear better ideas.

LOL, that was going to be my suggestion.

4thtry

Carefully make a set of forms around the missing material, kind of like the forms used to hold cement in place until it cures. I use blue masking tape to make my temporary forms. Then mix up a batch of sawdust and wood glue and trowl the mixture in place, just like you are pouring cement. Leave it dry for at least 48 hours, then sand it down to the original shape. That is what I have done many times and it seems to work well.

Impious

@4thtry said:
Carefully make a set of forms around the missing material, kind of like the forms used to hold cement in place until it cures. I use blue masking tape to make my temporary forms. Then mix up a batch of sawdust and wood glue and trowl the mixture in place, just like you are pouring cement. Leave it dry for at least 48 hours, then sand it down to the original shape. That is what I have done many times and it seems to work well.

Good suggestion. I dont have a dust collection system so it may be difficult for me to gather sufficient sawdust to make this happen.

DrewsBrews

I have had pretty much the same issue when swapping out a larger press-in port for a smaller precision port. The flange was able to cover the edge, but the screw holes were only half covered by material. I shaped some wood chunks to roughly the same radius as the hole and glued them in place. I used pieces of a paint stir stick (the large 1/4" thick ones for 5gallon paint buckets). Sometimes you can score em for free if ya woo the paint desk lady.

A pic gluing the first two pieces in:
Needs a small enough clamp to fit. Flip the jaw around to press outwards instead.

Impious

Stir sticks are a good idea. That might be easier than the toothpicks