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I made some small custom 3u boats to accompany my diy serge system.
The process follows what I’ve done for some years now:
In this case 1/8” Baltic birch was used for all boats: power/format conversion, 3u case, and format conversion.
The new format converter is direct banana to 3.5mm jack. I previously explored voltage scaling but it doesn’t seem to be needed for serge in most cases.
For the 3u and power boats I use blank panels when glue to ensure the sides aren’t bowed by clamping force. Recently I’ve seen some tests of glue strength with different clamping forces that leads me to believe that minimal force to hold in place would be sufficient, rather than the ~75-100lbs of force I’ve been using.
Everything turned out nicely but with two gotchas. Both power and format conversion boats are extremely lightweight, so lightweight that removing a cable lifts them up. So ideally these would be mechanically attached to a heavier object or integrated into a larger boat.
Pictures below show my process.