New Sub Project - AV15 *PIC*

[tomzarbo]

Re: New Sub Project - AV15 *PIC*

You've inspired me to get myself in the basement and finish my own (much smaller) version of a curved sub box. I'm at the point where I need to attach the sides (1/2" MDF, 4 layers per side). Thanks for inspiring me!
TomZ

[djarchow]

Re: New Sub Project - AV15 *PIC*

Jason,

Here is a jig I used on my curved sub and center for trimming the sides off at the front and back. I have seen these called a banjo jig.

I cut a piece of 1/4” and a piece of 1/2" plywood in the same shape as a jasper jig including the hole for the router bit to go through. Then I cut off the end of the 1/2" inch thick piece just behind the hole that the router bit passes though. I glued these two pieces together and screwed them to my router with the 1/4" side against the router base plate.

So the jig is 3/4" thick but when you get close to the router bit, it is only 1/4" thick which leaves a 1/2" gap between the wood or work surface and the router. Then with a 1" mortising bit set 1/32" above the baffle of the speaker, I can simply slide this jig across the baffle surface and trim off the protruding sides using my router.

Regards,

Dennis

[Wolf]

Got a picture?

I don't seem to follow your explanation very well.
Thanks,
Wolf

[djarchow]

Re: Got a picture?

I don't seem to follow your explanation very well.
Thanks,
Wolf

Yeah, it was clear as mud. Maybe this pic will help. Imagne the router mounted on top with the bit in it and oriented just like it is now. I use this for flush trimming but joints on cabinets where the the two panels don't meet at 90 degrees, for example, a curved cabinet.

Regards,

Dennis

PS the new board censors the proper spelling of but joint

[Jason]

Nearing the home stretch

Tonight I got the front baffle installed, routed the ports and driver opening, and gave the thing a test run. I borrowed a QSC USA 900 amp just to see what the driver would do with lots of power. I did the obligatory pod race scene, and got the amp's fan to kick in promptly, although the driver barely flinched. It appears I'm going to have to get a big amp to go with this thing, as I think anything under 1000W just isn't going to cut it.









Mostly just finish work now, which I'm sure will take just as long as the rest of the build up to this point.

[tomzarbo]

Re: Looks good

Jason,
that is starting to shape up pretty good. I see that you used plywood for most of the construction. I'm starting to become a little disenchanted with MDF because of all the stinky dust. I may have to use some ply or particle board next time.

By the way, you probably knew this, but... the PE 1,000 watt sub amp is on sale...

http://www.partsexpress.com/pe/showdetl.cfm?&Partnumber=300-808

Also, I think I remember seeing the rack mount version on sale as well in the flyer. You may need a more unflappable amp for your that aluminum-coned beast though.

TomZ

[eyekode]

Re: Got a picture?

Yeah, it was clear as mud. Maybe this pic will help. Imagne the router mounted on top with the bit in it and oriented just like it is now. I use this for flush trimming but joints on cabinets where the the two panels don't meet at 90 degrees, for example, a curved cabinet.

Regards,

Dennis

PS the new board censors the proper spelling of but joint

I thought about doing a very similar thing. But why use the 1/4 piece on the top? I would worry it would flex too much. Would need to buy some longer screws for the router base, but no big deal.

[eyekode]

Re: New Sub Project - AV15 *PIC*

How do you plan on doing the veneer on a curved surface? I have heard it is tough to get it to stick without a vacuum press...

[djarchow]

Re: Got a picture?

I thought about doing a very similar thing. But why use the 1/4 piece on the top? I would worry it would flex too much. Would need to buy some longer screws for the router base, but no big deal.

Since more than half of the router base is screwed to the 3/4" piece, there is little flex to worry about. The 1/4" thick overhang is just for the additional screws into the base plate of the router.

Regards,

Dennis

[Jason]

Re: Got a picture?

Yeah, it was clear as mud. Maybe this pic will help. Imagne the router mounted on top with the bit in it and oriented just like it is now. I use this for flush trimming but joints on cabinets where the the two panels don't meet at 90 degrees, for example, a curved cabinet.

Regards,

Dennis

PS the new board censors the proper spelling of but joint

Thought I'd resurface this thread to thank Dennis for this great idea for trimming the overhang on curved cabinets. I'll post a pic tonight of the baseplate I built for my router. It only took a few minutes to slap together, and it works great! Much easier than the method I was using... circular saw, flush trim, hand plane and then a LOT of sanding. Now I just use the one router bit and all that's left is a little filling and sanding.

[Jason]

Re: New Sub Project - AV15 *PIC*

Thought I'd resurface this old thread - I'm trying to make it the longest running thread in history ;) There's been some discussion about Acoustic Elegance drivers recently, so I thought someone might be vaguely interested.

Anyway, I've been able to get back to work on the sub and finally have some veneer on it. I need to vacuum out the remaining saw dust from inside and caulk the joints, and then I'll be ready to spray some finish. I'm looking forward to having this thing operational... and it's actually getting "close".

[andykriech]

Re: New Sub Project - AV15 *PIC*

Hi Jason, its looking very good. You are coming into the home stretch.

In your previous post, you mentioned taking a pic of the router base, were you still planning on doing that? I would also really like to see a pic of how you utilized it (put the router on the box to show how you used it). I am having a tough time visualizing its usage.

Thanks, Andy.

[Jason]

Re: New Sub Project - AV15 *PIC*



This is kind of a crappy pic, but hopefully it will get the point across. The blurry plywood is what makes up the new base. There's a 1/4" thick piece that mounts to the router, and a 3/4" thick piece that mounts to that. The router bit is "exposed", and the depth is set to flush with the flat face of the cabinet. The router sits on the flat face, and you run it along the overhanging edge to nibble away the overhang so that it's flush with the face.

That description pretty much sucks, so I hope the picture really is worth a thousand words :p

[andykriech]

Re: New Sub Project - AV15 *PIC*

Thanks Jason, that is great. Now I see what youwere talking about. Very obvious, must of had a mental block going ;-)

Andy.

[Jason]

Re: New Sub Project - AV15 *PIC*

Well, after nearly a freaking year, I've finally finished this thing. I've been living without a sub since last Christmas, so it's about time I got this thing done. I just ordered a blu-ray player, and wanted to have the full surround setup ready to go when it got here.



For the time being it will be powered by an old QSC USA900 amp, although I doubt that will last long as the fan on the thing is ridiculously loud. I'll probably end up with a Behringer EP2500 eventually.



Haven't had a chance to give it a proper run through yet, but I did a quick test run of it several months ago and it rumbled nicely. The cabinet had a lot of air leaks at the time, so I'm expecting much better performance this time around.