Two-Way Version 2 build thread

[Geoff Millar]

These look absolutely brilliant, they should also sound pretty good as you've chosen excellent drivers.

Value!

Geoff

[DeZZar]

Thanks Geoff. I was really impressed with the results from this driver combo. There were moments in the original build where I was concerned I might not have chosen well but in the end they do sound really good together. I'm hoping with the changes to the bass alignment along with the other treatments they will be even better. This version has significantly less group delay and the alignment should yield even better dynamics. I'm also hoping the more aggressive rounding on the front panel will help smooth things out even more although the first version did already achieve +-1-2db across the range :D

[Geoff Millar]

I used the RS180P-8 and it sounds excellent, plus it looks really cool with that phase plug.

Geoff

[DeZZar]

Both baffles fitted, and the port transitions smoothed over. Now time for the sides...


Temporarily fixed the port in place to start testing FB



Temporarily attached the sides and fitted the woofer. Few iterations of FB testing later the port has gotten 75mm shorter than modelled! Might leave it there....

[jhollander]

I was hopping for clear sides

[DeZZar]

I was hopping for clear sides

Hahaha! Maybe one day if I'm really bored and feeling the need for some cheesy bluetooth party speaker that glows in time to the music or something!

[jhollander]

Not sure it would be cheesy if you do the same level of craftsmanship, it's quite impressive and would be cool to show off.

[DeZZar]

Side panels fixed temporarily in place so they can be rounded over with the entire box.

Top and bottom edges received a 36mm (1.4inch) round over and the sides 25mm (1inch).


After much sanding and smoothing both boxes nearly done. A couple of little minor areas to fix up just to make sure nothing shows through the leather wrap.

[Steve Lee]

Very competent work.

[DeZZar]

Cutouts and recess made for the rear panels. This is designed to hold the crossover and speaker terminals.

Plan is to have a removable gloss black painted panel screwed in here for a bit of contrast to the leather.

[mattk]

Hahaha! Maybe one day if I'm really bored and feeling the need for some cheesy bluetooth party speaker that glows in time to the music or something!

Transparent wood:

https://theconversation.com/transparent-wood-is-coming-and-it-could-make-an-energy-efficient-alternative-to-glass-154981

[DeZZar]

Transparent wood:

https://theconversation.com/transparent-wood-is-coming-and-it-could-make-an-energy-efficient-alternative-to-glass-154981

Definitely cool. Technically a dried layer of cellulose lacquer could be considered clear wood.

[DeZZar]

Now that all the round overs are done its time to remove the sides and start cutting the recesses in the back edges for the leather wrap.

In the meantime I also marked and pre-drilled holes for the screws. The sides will be glued down but the screws will act as clamps and make sure there is a tight seal during the final glue up.


Because of the curved profile I wanted to carry that theme into the shape of the timber panels that will go on the sides. But cutting a small curve here would be a rather painful task so I decided instead to print these small plastic profiles and glue them in. This way is a consistent shape and no mucking around with fiddley little bits of wood.


On the back edge of the side panels and the joining surface on the box a small 0.7mm deep rabbit is cut on the router table first, and then a dovetail router bit adds the additional gutter for the leather wrap.


The gutter is especially for the corner profile and gives somewhere for the 'bunched up' leather to live without getting in the way.

[DeZZar]

Marking out the position and where to lay glue down for the sides. The panel is centered on the leather piece and then the sides folded up to mark the wrapped width. This leaves you with an outline of where to place glue and a refence to lay the panel back down once the glue is applied.


Applying contact adhesive to both the panel and the leather.


Panel then gets laid down on top again the edges drawn up around the sides.


Flip it over, press and smooth the leather in place and then trim the excess from the center.

[DeZZar]

Excess trimmed from the center.


After making some relief cuts in the corners the edges can be folded in and then given a final trim.

[DeZZar]

Now they can be flipped back over and glue applied to the recessed area.


Stretching and smoothing the leather in place. Here you can see how the recess makes that a lot easier.


Then a final trim. Again made really easy with the recess as you can just run the knife down the groove.


Ta-da two sides panels ready to go. Now onto the cabinet body!

[Steve Lee]

Fabulous!

Thanks for sharing this technique.