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DIY woofer with DIY Ti voice coil

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  • DIY woofer with DIY Ti voice coil

    I have been tinkering with making drivers lately and it’s a ton of fun. I’ve made a quad of subs and am working on something that can be used more as a woofer.

    One of my hang ups in making more of a woofer than a sub is the voice coils available to the average joe. The easily available ones are typically sub coils, which means long wind lengths and/or four plus layers. This is all fine and dandy for some circumstances, but can make for low sensitivity, high qes/qts, and high inductance.

    Some normal coils are available, but not typically what I’m looking for and may need to come from China. China isn’t a big deal but I hate the unknown and long shipping times for a product of unknown quality. I looked into having them wound at a place like Precision Econowind, but the MOQ is prohibitive.

    I turned to the encyclopedia that has taught me so many skills - YouTube, and started considering DIYing a coil.

    Ebay had the titanium, since thats what the cool kids are into, and the magnet wire.

    I made a “winding machine” from a piece of aluminum tubing, drill, some scrap wood, and misc fasteners. Worked out ok.

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  • #2
    I used standard temp wire since it isn’t a sub and the motor and frame I’m using is substantially vented (gap, pole, and under spider).

    I went with a 28mm wind length, which gives me 9mm of overhang. This is still a bit much, I was shooting for 6, but miscalculated a bit on the wire DCR, and the 22mm wind was too low. I made two practice coils first to dial in the length and get the hang of it. It is a two layer coil. I used regular 5 minute epoxy to adhere the wire.

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    • #3
      The collar is simply copy paper adhered and reinforced with the same adhesive I use to assemble the driver. If this were a high power application I’d choose a material with a higher ignition point, but this is nice and light, and the wire insulation will fail at 311 degF, long before the paper.

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      • #4
        This is beyond fascinating. I didn't realize a person could DIY an entire driver. How do you build the rest of it? basket, magnets, shortening rings, spider, etc?
        "I don't know everything and do not claim to. I continue to learn and that is what makes me human."

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        • #5
          I used the same motor as I used for my Annihil8 project. It’s nice because it’s relatively cheap and is an exact fit for these frames.

          Downside is it is unnecessarily large and has a massive gap. This is nice if you want to shove an 8-layer coil in there or need a ton of slop room, but when you don’t the qes suffers.

          I did use it to my advantage to hammer in a copper sleeve. The pole is too big to allow it between it and the coil, and can’t be turned down on the preassembled motor. I found that if I get a 2” copper pipe coupling sleeve and take it down some in a drill press with some emery cloth I can press fit it to shroud the coil.

          Im sure it is not nearly as effective as if I could get it between the pole and coil, but does provide a place for some stray currents to short and also provides some heat sinking.

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          • #6
            Assembly photos:

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            • #7
              Finished photos:

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              • #8
                Measurements and sims:

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                • #10
                  Originally posted by STIchris722 View Post
                  This is beyond fascinating. I didn't realize a person could DIY an entire driver. How do you build the rest of it? basket, magnets, shortening rings, spider, etc?
                  Yeah it’s a fun twist in DIY, something different. I’ve been wanting to tinker with this for a while and saw another forum gentleman (hifiside) make some pretty sweet drivers so I got some info from him and gave it a shot. All the parts are “off the shelf” and can be found on the great world of eBay. The materials for the coil came from eBay as well. The copper ring is actually just a copper dwv pipe coupler from menards that I “turned down” on a drill press with some sanding cloth.

                  With parts like this it is a total guessing game as to your outcome. I’ve been lucky so far with a couple drivers and have destructed a couple of unworthy ones already too.

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                  • #11
                    Originally posted by tomzarbo View Post
                    Geeze!
                    I mean that in a good way.
                    TomZ
                    Thanks Tom!

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