Two-Way Version 2 build thread

[Paul K.]

A number of years ago I made some accessories out of scrap 3/4" plywood that helped get panels clamped nicely flat.
Paul

[DeZZar]

A number of years ago I made some accessories out of scrap 3/4" plywood that helped get panels clamped nicely flat.
Paul

Yeah perfect. So much better than dropping a whole pay cheque on this stupidity https://www.logosol.com.au/product/g...tart-up-kit-2/

[DeZZar]

Cutting the rear insert panels now for the back of the speakers. I created this rear compartment with enough room to comfortably hold a crossover with quality (large) parts and easily access it in the future. Its also sufficient space to potentially explore active options should a future owner choose to.



One of the challenges with this build is that there are a number of instances of various sized outer radius cuts to be made. You could cut them by hand, sand them away on a disc sander etc but there is very little likelihood of getting multiple corners exactly the same.

This is why I think a 3D printer is actually one of the most important tools in my shop. Your only usually an hour away from any jig, guide or template you need. In side case a perfect 16mm radius corner.


Took about 15min to design and an hour to print and we have easy repeatability.

This will be even more important for the inset side panels on this build which need to fit a tight radiused corner very precisely.

11mm version of the side panels - test passed.


That's the result I'm after!


For the cost of a 3D printer (less than a lot of tools) it has paid for itself so many times already! Cannot recommend highly enough!

[a4eaudio]

Pretty clever corner jigs. Rockler has something kind of similar that is nice but kind of pricey, and I see its gone from about $60 to $80 rockler-corner-radius-routing-templates

[Colonel7]

Fantastic build and techniques. What 3D printer did you go with? There's so many choices now and difficult to sift through.

[DeZZar]

Fantastic build and techniques. What 3D printer did you go with? There's so many choices now and difficult to sift through.

I grabbed an Ender3 Pro from BangGood. Cost about $350. I purchased a few little upgraded parts for it as well which are all just swap/plug and play - probably only about another 20-30 bucks worth. Its been a really good and reliable little machine.

[Colonel7]

Thanks - good info!

[DeZZar]

Pretty clever corner jigs. Rockler has something kind of similar that is nice but kind of pricey, and I see its gone from about $60 to $80 rockler-corner-radius-routing-templates

Thanks. Yeah they are very similar to the rockler ones but by comparison take an hour to get to me and cost $0.34 to print At those prices I could pay for the printer by printing just 5 of these templates!

I could probably start a whole other thread just covering what the printer has been useful for!!

[DeZZar]

So without starting a new thread this is what a "cheap" 3D printer has been good for in my shop. I think its paid for itself well and truly!!

...

EDIT: New thread started instead of posting it all here: http://techtalk.parts-express.com/fo...-for-workshops

[Steve Lee]

I agree! START A NEW THREAD with your PRINTER PROJECTS!

PLEASE?

[DeZZar]

OK! New thread started!

[3rutu5]

Bring on the 3d.printed thread, warning it is an addiction

[DeZZar]

After a lot of routing and sanding the side panels are finally prepared and this is what they are looking like with a couple coats of Scandinavian Oil (yep, that's what Danish Oil is called here now - did the Danes get offended or something?)



Plan from here is to allow this to set/cure for a couple of days, then apply clear gain filler and then begin the process of applying varnish. I ended up going with a clear gloss UV resistant marine varnish.

I've tried this with a test piece and so far so good. I guess we'll see how it turns out on the large pieces.

[DeZZar]

Over here in the UK we have stuff called PU18 that works very well...

Cant find any PU18 specifically down under but I think it might be similar to this sort of thing:

• 3M version: https://www.3m.com.au/3M/en_AU/p/d/b40066976/
• Rust-oleum version: https://www.rustoleum.com.au/product...e-and-sealant/

I might just grab whichever of these I can find in store and try it out on a couple of scrap boards

[fatmarley]

Cant find any PU18 specifically down under but I think it might be similar to this sort of thing:

• 3M version: https://www.3m.com.au/3M/en_AU/p/d/b40066976/
• Rust-oleum version: https://www.rustoleum.com.au/product...e-and-sealant/

I might just grab whichever of these I can find in store and try it out on a couple of scrap boards

I don't know about the 3M version, but rustoleum says permanently flexible in the datasheet, so that's what I'd go for.

When you squeeze some out of the tube and let it cure, you should be able to stretch it apart, and when you let go, it should slowly return back to shape. Obviously it's no good if it goes hard when cured, or if it springs back into place as something like silicone sealant would.

[JonathanPenner]

That wood is stunning! Those speakers are going to look really sharp when they’re all buttoned up.

[DeZZar]

Thank you. I really like this wood as well. Hopefully don't screw up any of the finishing! :P

[DeZZar]

Just a quick update on this build. Side panels are coming along nicely. This is the process so far...

- Bare timber sanded to 240
- Two coats of Danish Oil (the version I have smells to me like a linseed oil base)
- Allow to cure for 24 hours
- Two coats of Aqua Coat clear gain filler (sanding between coats @240)
- Two more coats of Danish Oil
- First coat of Marine High Gloss varnish
- Sand back @240
- Second coat of varnish




Process yet to be completed:
- Two more coats of varnish sanding to 400 between coats
- Final coat of varnish
- Allow to fully cure
- Sand to 2000
- Polish
- Wax and Buff

Bit of a lengthy process but I think it'll be worth it

[djg]

That is some nice work.

[DeZZar]

Thank you djg. Hopefully these side panels still fit in place after all these coats of varnish lol!

[tktran]

Really enjoy watching this build. That cabinets looks like a million bucks.

[DeZZar]

Really enjoy watching this build. That cabinets looks like a million bucks.

Thanks mate. Happy to share the process.

[DeZZar]

Just a quick update on this....

The finishing process is by far the most time consuming. I'm another couple of coats into the varnish with a couple to go, and then the long wait for it to cure before cutting it back and polishing.....but its coming along nicely.

I've painted the rear inset panels from post #48 with a couple of coats of primer and then some matte black. These will get a final coat with tinted self leveling table top epoxy (fastest way to a dead flat super smooth polish-able surface!)


And I realize I hadn't actually posted a picture of what the speakers look like with both sides on, so this is how they are looking at the moment patiently waiting for the timber side panels!