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Building a Crossover (not designing a crossover)

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  • Building a Crossover (not designing a crossover)

    My Home Theater Build thread
    My DIY Speaker builds

    My Gear:
    Emotiva XMC-1
    Emotiva XPR-2
    Emotiva XPA-5
    Clearwave Dynamics 4T and 4CC (mains)
    Paradigm Millennia LP (surrounds)
    Oppo 103D
    Mede8er 600X3D w/ 4TB
    Marantz CD-5004
    AppleTV
    JVC RS-4910 Projector
    100" Screen Innovations Pure Gray Screen w/ LED kit
    APC Uninterrupted Power Supply (x2)
    iRule controlling it all....

  • #2
    Re: Building a Crossover (not designing a crossover)

    There are certainly better looking crossovers than mine out there, but I'll post some of my work. I secure the components with hot glue and zip ties. I like using terminal strips to make hookup and possible removal easy. I use solid core copper wire behind the boards to make any connections.

    ZDT3 (I have since changed out the screws holding down the large ferrite core inductor to zip ties. Using screws is a no-no in such a situation.)



    ZDT3.5



    ZDT3.5 Center Channel



    General wiring layout behind the ZDT3.5 crossovers above. Red is positive to a component, white is ground to a component, blue is a path straight to ground.



    You may need a login to see these pictures, but check out these:

    http://www.htguide.com/forum/showpos...2&postcount=56

    Comment


    • #3
      Re: Building a Crossover (not designing a crossover)

      Thanks for the pics. This is really helpful and helping me understand even more about crossover building.
      My Home Theater Build thread
      My DIY Speaker builds

      My Gear:
      Emotiva XMC-1
      Emotiva XPR-2
      Emotiva XPA-5
      Clearwave Dynamics 4T and 4CC (mains)
      Paradigm Millennia LP (surrounds)
      Oppo 103D
      Mede8er 600X3D w/ 4TB
      Marantz CD-5004
      AppleTV
      JVC RS-4910 Projector
      100" Screen Innovations Pure Gray Screen w/ LED kit
      APC Uninterrupted Power Supply (x2)
      iRule controlling it all....

      Comment


      • #4
        Re: Building a Crossover (not designing a crossover)

        I think that plain old hot glue and cardboard works really well...

        The cardboard is easy to cut, and hot glue sticks extremely well to it.

        Not gonna win any beauty contests, but it gets the job done. Easy and cheap.

        (yes, I realize the inductors aren't optimally configured in this pic...)

        Comment


        • #5
          Re: Building a Crossover (not designing a crossover)

          I've used hot glue several times, works great. But if you ever decide for whatever reason to dismantle/change the crossover, you might have difficulty pulling the components off of the solid glue. I prefer to use double stick tape to hold down my components. Easier to peel it off if you ever need to.


          Originally posted by lunchmoney View Post
          I think that plain old hot glue and cardboard works really well...

          The cardboard is easy to cut, and hot glue sticks extremely well to it.

          Not gonna win any beauty contests, but it gets the job done. Easy and cheap.

          (yes, I realize the inductors aren't optimally configured in this pic...)

          Comment


          • #6
            Re: Building a Crossover (not designing a crossover)

            Lots'a way to skin a cat, as they say. I like to run a common ground down the center of my x/o board and build off that. As mentioned before, it doesn't have to be pretty, just well soldered! This is one I whipped up for testing - would have shown you the 'final' version but I never photographed it!
            Attached Files

            Comment


            • #7
              Re: Building a Crossover (not designing a crossover)

              If you search for a thread entitled: "Physical Xover pics, post 'em if ya got 'em", you'll find a mess-load of pictures. It's a good thread in regards to building them.

              Curt C's site has a tutorial, as well as PE having one in their technical pages.

              I like peg-board and zipties, maybe some glue if required. Point to point soldering is the best and shortest path, and keep Inductors at a right-angle.

              Here's a recent one:


              Later,
              Wolf
              "Wolf, you shall now be known as "King of the Zip ties." -Pete00t
              "Wolf and speakers equivalent to Picasso and 'Blue'" -dantheman
              "He is a true ambassador for this forum and speaker DIY in general." -Ed Froste
              "We're all in this together, so keep your stick on the ice!" - Red Green aka Steve Smith

              *InDIYana event website*

              Photobucket pages:
              https://app.photobucket.com/u/wolf_teeth_speaker

              My blog/writeups/thoughts here at PE:
              http://techtalk.parts-express.com/blog.php?u=4102

              Comment


              • #8
                Re: Building a Crossover (not designing a crossover)

                Here's a pic of my ZMV5 crossovers when they were under construction.



                Note the strips of wood on the bottom. When wiring the crossovers, they elevate the board from the table so that twisted-but-not-yet-soldered wires don't get bumped loose on the bottom. Later, I just put wood glue on the bottom of the wooden strips and dropped the assembly into the cabinet to glue the crossover inside. The screws in the corners of the crossover boards let me remove them if I need to later.

                I used nylon screws and nuts to attach the solder strips on this build because I know that an inductor may be placed nearby. I didn't want the hunk of steel affecting the inductance.

                While I used Radio Shack solder terminals on this build, NEVER AGAIN! The holes are simply too small for more than two wires at a time. (Anyone know of another supplier of solder terminals?)
                Bill Schneider
                -+-+-+-+-
                www.afterness.com/audio

                Comment


                • #9
                  Re: Building a Crossover (not designing a crossover)

                  Yet another option . . .
                  Attached Files
                  Dave H

                  Comment


                  • #10
                    Re: Building a Crossover (not designing a crossover)

                    Dave,

                    Those are brass nuts and bolts, right? Something about creating lots of little inductors with anything other than that...or so I've read....

                    Gotta admit, it's a pretty cool looking x/o!

                    Comment


                    • #11
                      Re: Building a Crossover (not designing a crossover)

                      Originally posted by Hackomatic View Post
                      Yet another option . . .
                      I haven't seen that option before! I've seen double-sided P-P Plexi in a card-slot before, but not that.
                      Later,
                      Wolf
                      "Wolf, you shall now be known as "King of the Zip ties." -Pete00t
                      "Wolf and speakers equivalent to Picasso and 'Blue'" -dantheman
                      "He is a true ambassador for this forum and speaker DIY in general." -Ed Froste
                      "We're all in this together, so keep your stick on the ice!" - Red Green aka Steve Smith

                      *InDIYana event website*

                      Photobucket pages:
                      https://app.photobucket.com/u/wolf_teeth_speaker

                      My blog/writeups/thoughts here at PE:
                      http://techtalk.parts-express.com/blog.php?u=4102

                      Comment


                      • #12
                        Re: Building a Crossover (not designing a crossover)

                        Yeah, all bass hardware . . I decided to do it this way only to make component swapping easy if necessary.

                        . . and because I had all the brass hardware!
                        Dave H

                        Comment


                        • #13
                          Re: Building a Crossover, pic-thread link added...

                          Originally posted by Hackomatic View Post
                          Yeah, all bass hardware . . I decided to do it this way only to make component swapping easy if necessary.

                          . . and because I had all the brass hardware!
                          I tend to do that a little as well, but on peg-board. 1/4-20 bolts and nuts with washers for connections, just installed through the holes. I only do it for the higher-cost projects though...





                          Here's the former thread with xover pics...
                          http://techtalk.parts-express.com/sh...cal+xover+pics

                          Later,
                          Wolf
                          "Wolf, you shall now be known as "King of the Zip ties." -Pete00t
                          "Wolf and speakers equivalent to Picasso and 'Blue'" -dantheman
                          "He is a true ambassador for this forum and speaker DIY in general." -Ed Froste
                          "We're all in this together, so keep your stick on the ice!" - Red Green aka Steve Smith

                          *InDIYana event website*

                          Photobucket pages:
                          https://app.photobucket.com/u/wolf_teeth_speaker

                          My blog/writeups/thoughts here at PE:
                          http://techtalk.parts-express.com/blog.php?u=4102

                          Comment


                          • #14
                            Re: Building a Crossover (not designing a crossover)

                            I built the BAMTM crossovers using project boards from Rat Shack.
                            Last edited by Steve Henry; 04-10-2011, 09:32 PM.
                            Audiophiles listen to the equipment, not the music.

                            Comment


                            • #15
                              Re: Building a Crossover (not designing a crossover)

                              So many great options. I'm getting excited to start my first crossover build. I'll be sure to post pictures of my process/progress once I get started.
                              My Home Theater Build thread
                              My DIY Speaker builds

                              My Gear:
                              Emotiva XMC-1
                              Emotiva XPR-2
                              Emotiva XPA-5
                              Clearwave Dynamics 4T and 4CC (mains)
                              Paradigm Millennia LP (surrounds)
                              Oppo 103D
                              Mede8er 600X3D w/ 4TB
                              Marantz CD-5004
                              AppleTV
                              JVC RS-4910 Projector
                              100" Screen Innovations Pure Gray Screen w/ LED kit
                              APC Uninterrupted Power Supply (x2)
                              iRule controlling it all....

                              Comment

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