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Overnight Sensations - Curved Cabinet

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  • Overnight Sensations - Curved Cabinet

    Since building a very satisfying pair of Overnight Sensations from ErichH's flat packs I've been noodling on the idea of building a curved cabinet set of OS MTM's.

    While curved cabinets are not new here, I thought it might be of value if I were to include drawings that can be used to replicate these cabinets. In addition, I'm going to describe how they can be built and veneered with basic tools.

    Since this thread is targeted at the less experienced it is worth talking about realistic build expectations. Since WWII improvements in manufacturing efficiency has created a world of consumers that are not familiar with the satisfaction of homemade craftsmanship or characteristics of handmade. There are some obvious exceptions to be found here.

    If you are new to woodworking expect to make mistakes. Do not set yourself up for failure by expecting machine made perfection. There is an adage that says 'The difference between a wood butcher and a craftsman is the ability to hide ones mistakes.' Every build will have misplaced cuts, splintered veneers and fisheyes in the finish. Deal with it, imperfections are a sign of handmade craftsmanship. A craftsman is almost always their own worst critic. OK, time to get off my soapbox...

    Attached are *.jpg files that can be printed full-size as cutting templates. DXF files that can be sent to a CNC shop are available for the asking. For this build I sent the DXF files to a local Car Audio shop. In return for my $125 I received 10 top/bottoms, 8 internal frames and 3 inner baffles. This is enough to build 3 MTM's and 2 TM's. A jigsaw, router with pattern bit and lots of sawdust later you can have the same frames for a lot less money.

    The inner baffles are primarily to provide rigidity while the sides are skinned. The more obsessed will miter both the front and back baffles, I did not. Once the first skins are on and glue cured you have a very rigid and strong structure.

    The attached photos respresent a couple of leisurely hours gluing and clamping. The next steps are to cleanup the joints with sandpaper and apply the first skins. Dimensions for the first skins are 9-3/4" x 16" x 1/8".

    Tomorrow I will share my frame glue-up procedure. Two 12", four 6" bar clamps and some blue painters tape are needed for each cabinet frame glue up. The HF, read China import, screw clamp type are fine. Till tomorrow...
    Attached Files
    If life were fair, Elvis would still be alive today and all the impersonators would be dead.
    ~ Johnny Carson

    Bungelow Ed's Photo Album http://techtalk.parts-express.com/album.php?u=8594

  • #2
    Re: Overnight Sensations - Curved Cabinet

    Subscribed!

    Comment


    • #3
      Re: Overnight Sensations - Curved Cabinet

      cool. nice contribution. what will you skin them with.
      " To me, the soundstage presentation is more about phase and distortion and less about size. However, when you talk about bass extension, there's no replacement for displacement". Tyger23. 4.2015

      Quote Originally Posted by hongrn. Oct 2014
      Do you realize that being an American is like winning the biggest jackpot ever??

      http://www.midwestaudioclub.com/spot...owell-simpson/
      http://s413.photobucket.com/albums/pp216/arlis/

      Comment


      • #4
        Re: Overnight Sensations - Curved Cabinet

        Definitely subscribing to this one - can't wait to see the progress and final build. I have two pairs on their way from Erich arriving next week. If they sound as amazing as everyone says, I'll definitely be looking to make more.

        Thanks,

        Comment


        • #5
          Re: Overnight Sensations - Curved Cabinet

          Originally posted by [email protected] View Post
          cool. nice contribution. what will you skin them with.
          Current plan is Wenge w/ lightly dyed quilted Big Leaf Maple baffles. Lots of opportunity to demonstrate veneer repair techniques.
          If life were fair, Elvis would still be alive today and all the impersonators would be dead.
          ~ Johnny Carson

          Bungelow Ed's Photo Album http://techtalk.parts-express.com/album.php?u=8594

          Comment


          • #6
            Re: Overnight Sensations - Curved Cabinet

            Originally posted by LucasDavenport View Post
            Definitely subscribing to this one - can't wait to see the progress and final build. I have two pairs on their way from Erich arriving next week. If they sound as amazing as everyone says, I'll definitely be looking to make more.

            Thanks,
            I have a pair of the TM's and a pair of Aura T-Lines in my loft. It's a hard call which to listen too. The OS's are a little less recessed, but not overly bright.

            My guess is that you will be very happy with the flat packs and with the OS's. Please post pic's and progress.
            If life were fair, Elvis would still be alive today and all the impersonators would be dead.
            ~ Johnny Carson

            Bungelow Ed's Photo Album http://techtalk.parts-express.com/album.php?u=8594

            Comment


            • #7
              Re: Overnight Sensations - Curved Cabinet

              I got home from Malaysia on Friday morning so my internal clock is a little out of wack. Add the time change and I was up and in the shop by 5:00AM this morning.

              Progress made, frames are glued up and first skins are clamped and drying now. The attached photos and following verbiage illustrates my method. There are others, equally as good. Use what makes sense, discard the rest.

              The mantra of the day is, 'painter's tape is my friend'. Use it wisely and freely and you will make your life easier.

              Start by laying out the frame locations on the front and rear baffles. I used 4-1/2" from each end. Place a pencil mark to locate the frames during the glue up. Start with the front baffle face down, place tape across the front face, long enough to reach up the frame sides. This is used to temporarily locate the frames. Apply glue, set the frames in place on the front baffle. Move the frame around slightly, with downward pressure, this distributes the glue and helps to reduce movement later. Wrap the tape around the frame sides with some light upward pressure. The pressure stretches the tape and increases the downward force. Work down the baffle repeating the steps until all four frames are in place. Apply glue to the frame tops and place the rear baffle in place. Starting at one end, align the frames and place tape over the baffle and down the frame sides. Again, stretch the tape.

              Clamps go on the center frames first, clamping from rear baffle to center brace. Next move one end off the edge of the table and clamp that end, front to rear baffle. Place the glue up diagonally across a table corner to apply the other end clamp. Next, roll the glue-up on it's side and apply two clamps from front baffle to center brace. You will need 2 short pieces of MDF to span the baffle sides. Study the picture and run through the steps before applying glue.

              If you are short on clamps, each glue-up should set for at least 30 minutes when using Titebond II. Your glue-ups should set overnight, 24 hours is better, before moving to the next step.
              Attached Files
              If life were fair, Elvis would still be alive today and all the impersonators would be dead.
              ~ Johnny Carson

              Bungelow Ed's Photo Album http://techtalk.parts-express.com/album.php?u=8594

              Comment


              • #8
                Re: Overnight Sensations - Curved Cabinet

                perhaps you will understand my intrest in your build.

                " To me, the soundstage presentation is more about phase and distortion and less about size. However, when you talk about bass extension, there's no replacement for displacement". Tyger23. 4.2015

                Quote Originally Posted by hongrn. Oct 2014
                Do you realize that being an American is like winning the biggest jackpot ever??

                http://www.midwestaudioclub.com/spot...owell-simpson/
                http://s413.photobucket.com/albums/pp216/arlis/

                Comment


                • #9
                  Re: Overnight Sensations - Curved Cabinet

                  Very nice -- easy to see you know what you're doing. Thanks for sharing the build details; I'm convinced that a lot of people derive a lot of benefit from the details. I'm subscribing too...
                  Tritrix HT:http://techtalk.parts-express.com/sh...d.php?t=222519
                  Dayton 12" Subwoofer: http://techtalk.parts-express.com/sh...d.php?t=222930
                  Overnight Sensations: http://techtalk.parts-express.com/sh...d.php?t=223751
                  Cerberus sub: http://techtalk.parts-express.com/sh...hlight=cerebus
                  Duellatis: http://techtalk.parts-express.com/sh...d.php?t=224943
                  NTN's: http://techtalk.parts-express.com/sh...d.php?t=227902

                  Comment


                  • #10
                    Re: Overnight Sensations - Curved Cabinet

                    Originally posted by [email protected] View Post
                    perhaps you will understand my intrest in your build.
                    Oh, I do understand. You and I are kindred spirits when it comes to speaker building. You just have more experience and expertise.

                    Now you have my interest piqued, what are you building? Is it an existing design or a new one of your own creation?
                    If life were fair, Elvis would still be alive today and all the impersonators would be dead.
                    ~ Johnny Carson

                    Bungelow Ed's Photo Album http://techtalk.parts-express.com/album.php?u=8594

                    Comment


                    • #11
                      Re: Overnight Sensations - Curved Cabinet

                      Originally posted by Soundslike View Post
                      Very nice -- easy to see you know what you're doing. Thanks for sharing the build details; I'm convinced that a lot of people derive a lot of benefit from the details. I'm subscribing too...
                      Much of what I know, or think I know, I've learned from reading build threads here. That includes your NTN build thread. The flush mount description is very informative. I subscribed on Friday.
                      If life were fair, Elvis would still be alive today and all the impersonators would be dead.
                      ~ Johnny Carson

                      Bungelow Ed's Photo Album http://techtalk.parts-express.com/album.php?u=8594

                      Comment


                      • #12
                        Re: Overnight Sensations - Curved Cabinet

                        Cabinet frames are complete and the first skins have been glued. Applying skins is sort of a 3 handed operation, which is a problem when my ever suffering wife is not available. So, I conceived a jig which I will be drawing in CAD and building this week. The implication is that there will be no forward progress on the cabinets until the jig is complete.

                        The "jig" as envisioned will hold the front baffle and two opposing side skins so that the narrow end can be drawn together similar to a Spanish windlass. Zip ties will replace rope in a traditional Spanish windlass and removable sticks will provide stiffness across the length of the skins. There are also provisions for accombodating various baffle widths and lengths. Expect drawing and photos by EOW.

                        The attached photos are of the MTM cabinets with skins. The center cabinet has two skins per side. THese skins were applied using the standard binding process. This has been covered many times here, using zip ties an/or band clamps. One of the downsides to this method is the possibility of creating hard spots on the cabinet sides where shims are used to force the skin into contact with the underlying layer. Since I will not be using this method going forward there are no photos or descriptions of how the installed skins were done.

                        My adhesive of choice for skinning the cabinets is Liquid Nails dispensed from a gallon can. Application is quick and relatively clean with a notched trowel. Open time is up to 45 minutes which provides lots of time for adjustments. Liquid Nails or similar products provide some gap filling qualities which is nice when skins don't fit perfectly.
                        Attached Files
                        If life were fair, Elvis would still be alive today and all the impersonators would be dead.
                        ~ Johnny Carson

                        Bungelow Ed's Photo Album http://techtalk.parts-express.com/album.php?u=8594

                        Comment


                        • #13
                          Re: Overnight Sensations - Curved Cabinet

                          the build thread is here.
                          http://techtalk.parts-express.com/sh...d.php?t=218438
                          " To me, the soundstage presentation is more about phase and distortion and less about size. However, when you talk about bass extension, there's no replacement for displacement". Tyger23. 4.2015

                          Quote Originally Posted by hongrn. Oct 2014
                          Do you realize that being an American is like winning the biggest jackpot ever??

                          http://www.midwestaudioclub.com/spot...owell-simpson/
                          http://s413.photobucket.com/albums/pp216/arlis/

                          Comment


                          • #14
                            Re: Overnight Sensations - Curved Cabinet

                            Looking forward to those drawings -- you've got a great build going on here. Those curved cabinets are making me realize I need, uh, expand my horizons.
                            Tritrix HT:http://techtalk.parts-express.com/sh...d.php?t=222519
                            Dayton 12" Subwoofer: http://techtalk.parts-express.com/sh...d.php?t=222930
                            Overnight Sensations: http://techtalk.parts-express.com/sh...d.php?t=223751
                            Cerberus sub: http://techtalk.parts-express.com/sh...hlight=cerebus
                            Duellatis: http://techtalk.parts-express.com/sh...d.php?t=224943
                            NTN's: http://techtalk.parts-express.com/sh...d.php?t=227902

                            Comment


                            • #15
                              Re: Overnight Sensations - Curved Cabinet

                              Well, today's mantra remains "painter's tape is my friend." If you don't already have a case of it in your shop your shop is incomplete, IMO.

                              In order to keep the build moving forward while the jig is developed I bought a sheet of 1/16" poplar bending ply. This stuff can be bent around these cabinets with hand grip pressure. A couple of small clamps and painter's tape is you need to skin your cabinets. That is with some caveats; I suggest the first and last skins be 1/8" hardboard and the clamps may be for my comfort rather than necessity. My recommendation for the inner and outer skins being HD is for durability. The inner skin makes the box a tension-ed monocoque while the outer skin is more resistant to denting than bending ply.

                              The attached photo is my dry run. After dinner I'm going to glue a set of skins on all 3 boxes. Based on my dry run I expect all 3 boxes to be skinned in about an hour. And all boxes will be ready for a final 1/8" HD skin by this weekend.
                              Attached Files
                              If life were fair, Elvis would still be alive today and all the impersonators would be dead.
                              ~ Johnny Carson

                              Bungelow Ed's Photo Album http://techtalk.parts-express.com/album.php?u=8594

                              Comment

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