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Alternative Baffle Material

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  • Ironman129
    started a topic Alternative Baffle Material

    Alternative Baffle Material

    I've been looking at different materials I could use for my baffles on the MoZi design. There will be a waveguide milled out of the baffle for a rear mounted AST2560. I came across "Faux Marble". Does anyone know what that is made out of? Could I use a corian counter top? There are some for sale that look to be an inch thick and with some cool designs.

  • hobbyhands
    replied
    Sol8d surface material is also good. And cut well with router. But dusty

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  • TN Allen
    replied
    I've used Epoxy in the past to laminate 1/4" Corian to plywood and end grain Balsa, this could be done to save the cost of 1/2 or 3/4". I wouldn't recommend this for panels more than ~18" though as Corian does expand with heat and might shear the glue line. The same can be done with stone, and might make an attractive cabinet if a solution were developed for milling the waveguide.

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  • Pete Schumacher
    replied
    As TN Allen said, with the correct adhesive the joints are invisible. May as well make the entire cabinet out of solid surface. .5" walls of solid surface will be a lot stronger than similar with ply or MDF, especially when you factor in the bracing.

    http://www.avonite.com/colors/

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  • TN Allen
    replied
    If you use the correct adhesive, you should not see the joints at all, that is a remarkable characteristic of these solid sufaces.

    If you glue up the baffles to produce vertical grain, to minimize shrinkage and expansion with changes of humidity, you can reduse the amount of lumber you need. Perhaps you've already thought of the shrinkage and expansion, and the need to build cabinets to accomodate this. It requires extra work, which is a nuisance, but can be worth the trouble.

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  • Ironman129
    replied

    That baffle is 1.5" thick at the guide, 1" thick elsewhere. It was made by laminating three .5" thick pieces.
    Once you sanded and buffed, could you see the lines where it was laminated together?

    TN Allen I agree that waveguides in natural wood look amazing. Thats what I was starting to look at Corian with a marble look to it. I need 4sf total for all 3 baffles. I might try and exotic wood.

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  • Pete Schumacher
    replied
    Originally posted by Ironman129 View Post
    How thick is that baffle? It looks like that it more than 1". Did you adhere multiple pieces together?
    That baffle is 1.5" thick at the guide, 1" thick elsewhere. It was made by laminating three .5" thick pieces.

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  • jhollander
    replied
    Cultured marble is a PITA to work with. I've never seen it polished back up after cutting. Corian or similar would be much better.

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  • TN Allen
    replied
    Waveguides bring out the grain in solid wood nicely. I use Corian in the throat to provide a more robust edge where the guide mates with the tweeter surround to avoid distorting the edge when sanding. It mills nicely, but the uniformity of its appearance doesn't appeal to me. It would be interesting to know what solid stone would cost.

    I suspect the fabrication cost will be high for a Corian baffle with a guide, most fabricators only work with fairly simple shapes.
    https://flic.kr/p/DZkE6m

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  • Ironman129
    replied
    How thick is that baffle? It looks like that it more than 1". Did you adhere multiple pieces together?

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  • Pete Schumacher
    replied
    Avonite is another solid surface material. LOTS of different looks.

    Corian and Avonite cut with the same tools used for machining wood. It's not as hard as aluminum.

    This is a Corian baffle cut on a CNC. Sanded and buffed, no paint.

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  • Ironman129
    replied
    Some of the Corian countertops with have a marble look to them, or specs to make them look like stone. I checked with the CNC shop and they can cut corian, but will those specs cause an issue in cutting? is Faux marble different than Corian that looks like marble?

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  • replied
    Originally posted by Ironman129 View Post
    I've been looking at different materials I could use for my baffles on the MoZi design. There will be a waveguide milled out of the baffle for a rear mounted AST2560. I came across "Faux Marble". Does anyone know what that is made out of? Could I use a corian counter top? There are some for sale that look to be an inch thick and with some cool designs.
    ​Cultured Marble would be great, but definitely more difficult to work with. I suppose that you'd need a lot of carbide tooling or even diamond blades to cut it. Then after cutting, you'd need to polish it again. Cultured Marble is a mixture of fiberglass resin and crushed limestone.

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  • wogg
    replied
    Folks were talking about Corian just the other day.

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