Assembling the Jack Box
To make these instructions easier to follow, acrylic with brown paper still on it is being used. If you peel the paper off of your pieces before gluing them together, you will have a transparent box through which you can see the electrical components.
Step 1: Glue the Box
Place the inner face (3) on the assembly jig. It can only fit on one way.
Glue the sides (5) to the inner face. Be careful not to also glue them to the assembly jig.
Once the glue has dried, remove the pieces from the jig, and glue on the other face as shown.
Place a bead of super glue along the notch in the top of each face and down the top of the sides. Press the top of the box into place. (Note: Gluing the top on before the glue on the inner face (4) is completely dried will help ensure that the corners of the box are square.)
Insert the nut into the corresponding hole on the inner face. From the inside of the box, place several drops of super glue around the edge to hold it in place.
Step 2: Wiring the Box
Cut two pieces of 20AWG wire about 3″ long and strip 1/2″ of insulation off of each end. Solder one end of each wire to the contacts on the 1/4″ jack.
To insert the jack into the box, feed the wire leads through the two holes in the inner face. Use them to pull the jack into the box. Then, push the threaded end of the jack through the hole in the outer face, place the washer over it, and tighten the nut to hold it in place.
Step 3: Attaching the Bottom
Slide the bottom of the box (1) into the slots on the sides. Place the washer on the screw, threat it into the nut on the inner face, and tighten it snugly.