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NE225W+PM180+ViaWave Design & Build Thread

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  • jml
    replied
    Originally posted by Wolf View Post
    Wow! If I had cut them all to 1" like you said, I would have made the top panel thicker to compensate and not made all of those adjustments 156 times.

    That's dedication to a form factor,
    Wolf
    That's a very fair point! Although, after investing 12-14 hours to cut and route each one of the staves, taking 30 minutes to run them all through the planer again didn't seem like an overly arduous task. Although I was a little afraid that after investing that much time in them, the planer was going to ruin them either via tear-out or planer snipe - luckily it was taking off such a small amount that none of them were ruined in the process.

    Cheers!

    Joe

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  • Wolf
    replied
    Wow! If I had cut them all to 1" like you said, I would have made the top panel thicker to compensate and not made all of those adjustments 156 times.

    That's dedication to a form factor,
    Wolf

    Leave a comment:


  • r-carpenter
    replied
    Yep. Wow is a good description!
    Very clean work too.

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  • Millstonemike
    replied
    Wow!

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  • craigk
    replied
    Very nice. Sent from my SCH-S968C using Tapatalk

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  • jml
    replied
    Happy Memorial Day All!

    Attached are some updated build pictures. All of the "staves" for the sides are complete and glued in place. Between the two speakers there are 156 staves. Over the course of all the operations to make each one, I probably lost about 15% to scrap due to tear-out, warped boards, excessive knots etc... The boards started out slightly over 1" thick, and in order to get them to stack up to exactly 39" I had to plane them down to .998" each. This process highlighted the issue of "stacked-tolerances", as I originally planed them down to exactly 1.000", but when stacked they required excessive clamping pressure to get them down to exactly 39".

    Now that this part of the project is done, I expect progress on the tops, bottoms, and baffles will come quickly.

    Cheers!

    Joe

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  • jml
    replied
    Roman:

    Thanks for the input on the wax. I hadn't thought about that aspect of it previously. I've finished projects of oak and ash previously with just stain and clear wax, but they haven't been around long enough to see what happens to the color over time. i'll definitely do some testing with spraying on a light coat of water-based finish and then rubbing on a thin coat of clear wax.

    Cheers!

    Joe

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  • r-carpenter
    replied
    Ambitious project! Looking forward to the progress.
    One comment on wax. Wax, by itself offers very little protection and tends to attract dust and dirt. If you would like to keep the color of the woof as unchanged as possible, waterborne coat of clear finish would do the trick. And top with a thin coat of wax.

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  • jml
    replied
    Thanks for the comments. The way that the curve exposes the wood grain on some pieces is pretty cool looking. I went through the stacks for all 4 sides today and pulled out some of the pieces that had large knots in them - the diversity in the grain between boards is all part of the look, but I decided that I didn't want them to look "rustic". At this point i'm thinking of leaving them natural in color and just rubbing on a clear wax finish.

    Hopefully I'll have updated pictures of the cabinets assembled within the next couple weeks.

    Best regards,

    Joe

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  • 6thplanet
    replied
    Cool, that should have a pretty unique look! I'm diggin it.

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  • bill poster
    replied
    Wow impressive work. Interesting choice of drivers too.

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  • jml
    replied
    Good Evening!

    i've started working on the exterior cabinet for this build. The sides will be a "faux translam" construction, which has been very labor intestine - 80 pieces per speaker.

    Attached is the sequence of operations to get the concave curve into each of the pieces. I haven't yet rounded over the corners, but I will be putting a 1.5" round over on all 4 corners. I'll also be putting a very small 45 degree bevel between all of the pieces in order to create a "v" between each 1" this piece.

    I haven't quite figured out if I want to pull out the boards with knots or leave them in. I'm also debating on staining them dark (like dark walnut or similar) or leaving them natural. What do you guys think?

    Cheers!

    Joe

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  • jml
    replied
    Good Evening!

    Just a quick update on this project. The inner cabinets are all glued up, and now it's on to the exterior and finish work.

    Cheers!

    Joe

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  • jml
    replied
    Good Afternoon!

    I finally have another update on this project. I got all of the panels for the "inner cabinet" of the design cut today. The cabinet panels interlock via a channel cut into the inner surface of the front and back baffle. There is 1/4" of overhang intentionally, as the "outer cabinet" panels will have a channel cut into them that interlocks over the overhang. The inner cabinet is MDF, and the outer cabinet will be real wood "cladding" varying in thickness from 1-2" for a total cabinet thickness of between 1-3/4" and 2-3/4" - with the exception of the front/rear baffles, which will be 2 layers of 3/4" MDF.

    The "double-interlocking" design should be extremely rigid when glued up. The one thing that I would do differently next time would be only going 1/8" deep with the channel. As the channel is 1/4" inch from the edge of the board, the "lip" at the edge of the board is relatively fragile, and it broke off while routing on one of the board. Only going 1/8" deep would have made the lip stronger, created less dust, and probably gotten 90% of the benefit of this construction.

    I would honestly consider using this construction again simply to make the glue up that much easier - you could glue it up, and then route the edge off with a flush-trim bit.

    Cheers!

    Joe

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  • johnnyrichards
    replied
    Re: NE225W+PM180+ViaWave Design & Build Thread

    Nothing drives home how much we listen to two or three watts almost exclusively than an SPL output chart. Once I decided to stop modeling for bleeding ears, I found it is okie-dokie to use smaller-than-ideal ports. I never even top 95db when drunk and listening to 80's hair bands these days, much less when listening for relaxation and emotion.

    Leave a comment:

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