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The Defiants - InDIYana 2019 Build

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  • KEtheredge87
    replied
    Putting a full 15" x 18" x 14" block of Bondo into a 5-axis CNC mill would be a glorious experiment... arguably a misuse of either technology, unless it works out great, then you're a pioneer! Trying to machine that much Bondo... what a mess! I'd pay to watch that.

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  • xmax
    replied
    Oh I see it now and it's still beyond reproach. I decided my next speakers are going to be made entirely
    from Bondo to save time.
    Last edited by xmax; 02-28-2019, 11:57 AM. Reason: Boredom.

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  • KEtheredge87
    replied
    Originally posted by xmax View Post
    Did you sand off my artwork?
    Haha... your artwork has actually been enshrined in the first YouTube video for all eagle eyed observers to find as an easter egg. I had to use the template pieces you made for me as templates to make the bigger MDF parts when my original tooling plans weren't as robust as I thought they'd be.

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  • xmax
    replied
    Did you sand off my artwork?

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  • KEtheredge87
    replied
    Hello Everyone - Defiants Curved Top - Part 2

    I made a YouTube follow-up for this part of the project showing how I fixed one of the cabinets that did not cut quite right with my method. As discussed above, the process failure here is more on the tooling setup I chose with two templates that are secured/supported in the air rather than solid all the way down to the table. All it takes is a little error in my measurements to mess that up. The new tooling works the same as the old tooling - just with less opportunity for me to mess it up. I wish I had taken a little more time to make my tooling in this manner rather than cobbling something together. Oh well... we live and learn!

    After the video was completed, I put some bondo glazing putty in the little pinholes rather than trying to do a whole "appropriate" layer of Evercoat. Tonight I'll finish that process and hopefully start prepping my front baffle blanks. I'm really ready to move forward!



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  • KEtheredge87
    replied
    Thanks Kevin K. , I hadn't seen one of those before, but I like it! Wen does not seem to make a riser block, so I'd have to DIY one. The saw is $250 stock, so I wonder if I'd be better off upgrading at some point rather than trying to chop and hack this saw together. Fun things to think about!

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  • Kevin K.
    replied
    Originally posted by KEtheredge87 View Post

    Thanks Kevin!

    "... they call em bandsaws" <-- that was awesome! I had the image in my head of you revealing a magical land hidden inside Rockler and Woodcraft stores where all the best tools were kept at the absurdly low prices.

    If I make a habit of this video thing, I should invest in a GoPro or something rather than put all that stuff on my phone's SSD. Also... yeah... I would LOVE a full size bandsaw! The little 10" WEN bandsaw I bought does most of the bandsaw-style things I need, but there's definitely room for improvement. You're right... If I could have fit this cabinet into the bandsaw saw AND confidently held it to cut a chunk off it would have saved a whole lot of time!
    Might check with the manufacturer of your bandsaw to see if they offer a riser block. Here's a picture of the one on the Delta I use. Been using this model for the last 20 years, awesome saws. With the 6" riser, there's a full 12" cut capability (second pic). I slapped the fence guide on the saw also for the picture, it really comes in handy sometimes. With your engineering background, I'm betting you could modify yours even if the riser isn't available from the manufacturer. This was one of the reasons I wanted to share the pictures with you. But don't let the idea of this get in the way of your current project, lol.

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  • KEtheredge87
    replied
    Alright guys - Last night I made some better quality and better supported curve templates with the router table. These ought to match up in height exactly to one another when I use them (maybe tomorrow?) In order to remove as many table-related variables as possible, I bought a brand new 1/2" particleboard piece (generally my router spoil-board), and set everything up on my tablesaw top. That's easily the flattest surface I have in the shop. The last detail to work out is supporting these big sheets of 3/4" MDF and locking the cabinet in place on the table top. Shouldn't be too hard, just need clamps and/or screws in the right place.

    With the improved "version 2.0" tooling mostly complete, I spent tonight pretending I was the "Cake Boss" with Evercoat bodyfiller. My theory was to slather a few layers of this stuff on to build up the side of the cabinet that trimmed too deep, so then I can router off the excess to achieve a flat, level top surface again. I was satisfied with the right corner of that cabinet, so I left it "un-iced" as my reference surface for setting my router bit depth. Everything else got a decent coating to make sure I had at least the 1/8" of space built up that I needed to replace.

    I'm letting all that stuff completely harden overnight. Instructions say it's good to sand within 20 minutes, but given how thick I laid it on (even though I gave it time between coats), I still want to let it set up overnight. I'll be sleeping anyway... Win/Win!

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  • KEtheredge87
    replied
    Originally posted by Kevin K. View Post
    Cool video Keith. You are a natural YouTuber and hopefully you'll make more videos in the future for the "up and comers" to watch and learn from. It's time for that next piece of equipment man, they call em bandsaws. ...Awesome work so far man!
    Thanks Kevin!

    "... they call em bandsaws" <-- that was awesome! I had the image in my head of you revealing a magical land hidden inside Rockler and Woodcraft stores where all the best tools were kept at the absurdly low prices.

    If I make a habit of this video thing, I should invest in a GoPro or something rather than put all that stuff on my phone's SSD. Also... yeah... I would LOVE a full size bandsaw! The little 10" WEN bandsaw I bought does most of the bandsaw-style things I need, but there's definitely room for improvement. You're right... If I could have fit this cabinet into the bandsaw saw AND confidently held it to cut a chunk off it would have saved a whole lot of time!

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  • Kevin K.
    replied
    Cool video Keith. You are a natural YouTuber and hopefully you'll make more videos in the future for the "up and comers" to watch and learn from.

    It's time for that next piece of equipment man, they call em bandsaws. I'm a fan of the Delta saws since they offer an optional riser block for taller cuts. You could knock some serious time off what you just did by rough cutting a big chunk of the material before routing. But hey, you made do with what you had to work with, kudos. After seeing the mess, I would recommend this be an outdoors only type project in the future. There's really not going to be a good way of capturing all the stuff flying around and who wants to spend an entire day cleaning up the shop afterwards. Awesome work so far man!

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  • KEtheredge87
    replied
    Alright Gentlemen... I give you the full video version of my curved router sled extravaganza, version 1.0. I've taken jhollander, Kevin K. , and tomzarbo 's comments into consideration and have started version 2.0 in order to correct my mishap with the second cabinet. I'll do a follow-up video on that one when I've gotten it all together!

    General setup and nerdery for the first 10 minutes or so. Sawdust flies at 10:30. Enjoy!

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  • Kevin K.
    replied
    Originally posted by jhollander View Post
    Kevin, I was thinking couldn't you do some cnc curved tops? I was thinking like a curved MDF wig I can glue on and trim the sides flush?
    Hey John, hope you are doing well. Yea, I cut a curved top on the Mystiques, just a different method. Keith is layering blocks and cutting the outside curve only. I cut the curve on both sides to maintain the same material thickness throughout. A bit of a pain to do though. The curved sidewalls of the Royale's were CNC cut as well, they started as 1-1/4" MDF and yielded 3/4" after the cuts, again, cut from both sides. I'd really like to build some jigs to vacuum bag the panels from 1/8" material. And then fixture cut them to size with the CNC. Hoping to have some time to play around with that later this year.

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  • jhollander
    replied
    Kevin, I was thinking couldn't you do some cnc curved tops? I was thinking like a curved MDF wig I can glue on and trim the sides flush?

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  • Kevin K.
    replied
    The curved tops look great Keith! I'm with Tom, work from the table surface up. If your fixture and cabinets are both indexed from the same surface, should yield consistent results.

    Looks like Tom won't be the only one borrowing your curved top method in the future. I'm envisioning the sidewalls of my Royale's with your curved top, should look pretty cool. KEF did some Coax's that look similar to your cabinets but their top curve was too subtle IMO, I like yours better. Keep plugging away man, looking forward to seeing these finished.
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  • tomzarbo
    replied
    Keith,
    I'm thinking that the only guarantee of getting exact results would be to have the sled setup go all the way to the table surface that the cabinet is setting on... otherwise it's a measuring game and there may be a chance for inconsistencies. I KNOW you measured and lined things up super carefully as is your custom. It looks good anyway, I'm sure you'll nail it on the re-do!
    Thanks for posting the process, I want to try this in the future.

    TomZ

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