Update on the N29 diffusers.
They are *bust* for now.
I spent about six hours on the first one today, hoping to finish up the "grid" so I can focus on making a better jig for the "tiles". I got down to the last 10 fins in the grid, and they just wouldn't fit. It's not that they were too tight, as I found earlier on, because I've introduced a little extra slop in my cuts. The problem comes from the "key" in the jig I made:
The problem lies in that I'm cutting 5 pieces at a time, sometimes more. And it turns out, the key is deflecting slightly. So the fins closes to the backbone of the jig are more consistent than the ones towards the other end of the key. They key deflects a little, and the 5th or 6th fins slots are slightly wider....and wider...and wider.
On a Prime 11, this wouldn't be a big deal as the incremental offset is minimal only 11 slots in. But when you get to the last 25-28, it's off by enough that it looks like a part for a completely different puzzle.
SO! This leaves me to do one of two things. Either scrap this project and just start churning out some 2' X 2' Prime 11 with 2.185" tiles, or I build a better, more stable jig and start an all new pair of prime 29.
I'm very frustrated in this...I should have seen this coming. Every issue I resolved only made me realize another issue. But this is what I get for attempting such a grand build...I feel like I'm building a space shuttle with Henry Ford's production line and tools. Either I need to create better tools, or reel in the project to something a little more realistic.
All that said, I've already got a design in my head for a better jig that will be several-fold more accurate. I'm just not sure I want to run out and buy another $60 of MDF and start all over for a show off project.