All it takes is a sketch

[6thplanet]

...and the cycle continues. We all do it, some at work, some at home, some on paper, some on the computer. This one happened at work and now has my mind rolling. It's going to have some nice aesthetics, a couple drivers I've never used, and a few construction methods I've wanted to try that I've never attempted. Up to bat in this build are the Usher 8945P (which thankful to a member on this board sold me a match to my one tent sale find a year ago) woofers and the Aurum Cantus APR2.1 tweeters (bought from PE on sale awhile back). Also I've had these aluminum port flares I bought from MCM years ago that I recently refound and have now become part of this roller coaster. The sketch on the left is the one I'll be pursuing in this build...

[Kevin K.]

Now that's a port with some flare! Excuse the pun. Subscribed.

[chrisn]

Nice drivers. Those woofers well in larger box like the one in the sketch.

[tomzarbo]

That's how most of my speakers come to be... "A doodle that deserved to become real" is how I put it.
Looking good so far!
TomZ

[SHYNOLA]

Was this inspired by the "miracle speaker" by Koonce and Wright, Speaker Builder magazine 6/96 ?

[jhollander]

Is that a concave section in the middle of a thick front baffle?

[6thplanet]

SHYNOLA, no, just a random idea.
John, yes, a tapered cove. This is one of the details I've wanted to try using the table saw.

[jimbones]

very interesting I can't wait to see the finished product and hear your review of them.

[6thplanet]

I played around with some scraps and stuff till I found a shape I liked. Then I made some cuts to see how it'll happen. The first jig was made to cut the baffle angle. The back top and bottom are all 90* and the bottom angle where the port will be is 45*. While in play mode I'm torn between a granite/marble base or one that might mimic the baffle...

[6thplanet]

Alright, the side panels are done. The jig worked like a champ, so with those complete next up will prolly be the bottom panels and top. I glued some scrap pieces to the sides to act as pseudo "rabbets" to help align the bottom and top. I like to try to use up scraps instead of just throwing them away, little "aids" like that are great use for cut off waste.

[6thplanet]

Ran the woofers through the DATS:
Re:5.5
Fs:41Hz
Qe:0.434
Qm:2.82
Qts:0.376
Le:0.115
Mms:17.66g
Vas:0.992cf ( 28.1L)
SPL:88.4
Sd:136cm2
As of right now it looks like around a 1.25cf box tuned to 35Hz (3"x10.25" port) will be a nice starting point. If my math is correct I should have about that right now.

[6thplanet]

Spent a few hours today cutting the bottom and tops for both cabs. Also, cut a blank for the backs. I was able to get one of them glued up.

[6thplanet]

This weekend I got the front and rear cleats installed. I'm using 3/4"x3/4" oak for the back, which will utilize threaded inserts for a removable installation as the speakers will eventually be rear mounted on the baffle. As for the front, I used some 3/4" aluminum angle to mount the solid hardwood baffle.

[6thplanet]

It cooled off a bit tonight so I hit the garage to make some headway on this project. I drilled all the holes and installed the threaded inserts to make the backs removable. Seams a bit over kill, prolly could have just used simple drywall screws, but what fun is that!!!
The hardware is good old Harbor Freight 1/4" allen head bolts/washers. I used a 5/8" Forstner bit to countersink the bolts. Next up will be to get a base and a baffle going, maybe this weekend. The "honey do" list looks like: kitchen counter top/faucet and security camera install.... << (that's my not getting to build speaker face)

[JavadS]

Awesome looking good! Javad