Synergy horn build

[jhollander]

Mark, back on post #24 Bill W. and I talk about how we want a small back chamber to drive the mid-box frequency higher. So, yes leave it small. The x-o is designed to flatten out the peaks.

[bwaslo]

jhollander, I just now saw the response you got on that. That is really impressive!

[jhollander]

Thanks Bill. You were a great help in making this happen. There is still room for improvement in the top end and cleaning up some of the honk.

[shrub0]

John,
I started my build of your design. So far I've got the top and bottom parts of the horn cut.

One question, on page 16 of the write up it's says cut a 1/2 inch board 27 inches long by 22.71cm. Should that be 27 cm by 22.71 cm?

[jhollander]

That is the jig fabrication instruction. You will need a board that is at least 27 inches long and 9 inches wide to be the table saw sled. Layout the 3 dimensions to get the angle cut.

[shrub0]

Thanks for the quick reply John. What size are the side boards before going into the 1st right angle jig?
Is it possible to cut a 22 degree bevel on one side of the side panels before putting it into the 1st jig to avoid building the second jig?

[jhollander]

Just re read that note. That instruction is for the side piece cutting. The base for the jig can be any size to accommodate the angles. So that means the the side piece started as 9 inch by 27 inches. I cut 45 degrees on both of the long edges and got the width down to 8.94" then ran them through the first 90 degree jig.

You would not need to make the second jig if you made two of the angle cutting jigs to be able to cut both sides of the relief cut. Like I said in an earlier post I made a lot a scrap cutting these parts. Good luck.

[shrub0]

I appreciate your help John.

I think what I was confused with is the bevel angle of the saw when using the side panel cutting jig. It should be 45 degrees correct?

So the second jig you are referring to would look like this?

[jhollander]

Not sure that's right. You would need a left hand and right hand jig, where one is flipped top to bottom. Like I said, I'd have to cut a bunch of parts to figure it out. I do know that what I drew up is what I used.

[shrub0]

Ok, but in response to my first question the saw is set at 45 when using the first jig?

[jhollander]

The first jig has the saw blade set at 90 degrees. The 45 degree angles have already been cut before you use the first jig.

[shrub0]

Ok I think the source of my confusion is this picture. Should'nt we be cutting the purple line at 22 degress?

[jhollander]

No, the purple line is the 45 degree angle you cut before you started using the jigs. The jig in your picture is the 22 degree relief cut jig. A better version of this jig has the hold down board extending al the way to the saw blade.

[shrub0]

Or is the 22 degree bevel shown in this picture in pink.

[jhollander]

Yes that shows the 22 degree relief cut.