My 1st build thread

[tom_s]

OK...not my first build, but my first time posting one. This design uses the Peerless HDS 832873 and the Vifa DQ25SC with the crossover that jkim designed in this thread- http://techtalk.parts-express.com/sh...=211207&page=2 I have already built a version using the BC25SC06 and that will go to my brother as a birthday present. He hasn't picked it up yet, so I'll have a chance to compare them directly.

Just like most of you, I started with a sheet of MDF. I had it cut into 3 pieces at Lowes and this one was 33" x 49"" making it easy to handle in my tiny shop. This version is going to be just a bit larger than than the 8.5 liters that Jay modeled. These are 8 x 14 x10" so with bracing and drivers, it should be around 11 liters. I hope a little more volume might give the impression of a little more punch to the low end of this woofer...we'll find out tomorrow.

I over-sized the initial cuts on the baffles and backs, using the same 8.5" for the depth of the sides and top/bottom cuts too! I only had to move the fence 4 times to cut all the pieces. The leftovers became the braces.

[tom_s]

Re: My 1st build thread

I saw Bill Schneider's slot cutter jig and thought that might cure my dislike for my old biscuit cutter. Crud!There were no holes to mount mine to a board and no good way to drill any without taking the thing apart. But I did find that I could use a few clamps to hold it tight. Thanks Bill-that trick made it simple to cut biscuit slots with no mishaps and no wandering pieces! That made glue up pretty easy.

So now on to the fun part-those truncated little woofers! I needed to make a template. Having made one for those BC tweeters, I had a plan - use my Jasper Jig to cut the overall countersink diameter, then run that piece through the table saw on each side and just glue some straight pieces on for the flats. Well, the first attempt ended with a slightly lopsided template. Guess I should have measured 4 times!! Then I remembered seeing that someone else had stopped short at the flats with the router when cutting the circle. That went well. Then I just finished cutting the flats, very carefully, with my router's edge guide. Test cut looked pretty good-not perfect, but good enough. Now I just needed to build a quick jig to hold the baffle in place. My pattern cutting bit is pretty long, so I needed some blocks to hold the template .75" above the baffle. I think I spent over 2 hours just putting the template and jig together- the actual routing only took about 2 minutes! But it's always good to add to your bag of tricks.

[tom_s]

Re: My 1st build thread

I had done the tweeter cutouts earlier. I ended up using a 1 7/8" Forstner bit and then wrapping a rabbeting bit with a few turns of electrical tape to get a snug fit. In hindsight, it might be too snug once I paint the baffles...

For the terminal cups, I used the Jasper Jig and over sized the cutout to 3 1/16th so my 1/2" rabbeting bit would just take off enough for a tight flush fit. The backs are glued and clamped, so I should be able to glue the corner blocks for the removable baffles in the morning and have them making some sound by the afternoon....I hope.

[Ryan_M]

Re: My 1st build thread

Love the jigging, I spend a lot of time jigging up for a cut that takes seconds too. Template work looks awesome too. The last photo looks like you have a bit of a hairy edge... maybe you owe it to yourself to get a shiny new (and sharp) router bit. Though could be the pic emphasizing the nasties. I like to do new stuff too every build to add to the 'bag of tricks'.

But on to the important stuff... that looks like a DIY zero clearance insert on your TS, hows that working out for you? I still have the stmped steel one and it is no end of frustration especially when working small parts that ride mostly on that plate. Care to spill the beans on how you set it up?

[tom_s]

Re: My 1st build thread

Yep..I do have some furry edges on those cuts. I really need to clean my bits and see if that helps. If not, there's place about 5 miles away that does a great job sharpening just about anything you can drag in!

The zero clearance insert is something that I made so long ago...I can't even remember! It's just some 1/4" oak ply that I taped to the factory insert and buzzed around with a template bit. It actually stays in place pretty well without any screws or clips. It's probably not perfectly level with the table anymore due to age and warp, but it works for most of what I do. I still have a few blanks somewhere here..and one for my wobble dado blade.

[[email protected]]

Re: My 1st build thread

i too get a sheet and have it sliced a bit oversized at hd. save a bunch of work.
looking real good so far.

[nick29498141]

Re: My 1st build thread

As Borat would say, "Great Success!" so far. Keep the pics and ideas comin' :D




:D

NK

[tom_s]

Re: My 1st build thread

Thanks Arlis. It seems like it's taking forever to get just the basic boxes built. But in reality, most of yesterday was spent on the baffles, making sure I didn't screw something up too much! I slept in a bit, but I'm back at it...for as long as my wife will let me....

[tom_s]

Re: My 1st build thread

Thanks Nick,

It's been slow going today. I did get the backs trimmed and sanded flush. Then I cut the corner blocks and just glued the second set-I only made 4 outside corner clamp blocks last time around, plus I don't have enough medium sized clamps to do both boxes at the same time. Hey...that might be an excuse to head over to HD or Lowes!!

I also used the Jasper Jig to make some small receivers for the port tubes- just 2" PVC. Those will be attached on inside, leaving the 2" hole on the outside to be rounded over slightly. That should allow me to try different port lengths, then I can glue the PVC in place once I decide these are ready for prime time!

[rogoll]

Re: My 1st build thread

Is that "Delta" logo I see on a dust collection system? I noticed that the local Lowe's has started carrying a Delta dust system. I was wondering, for a hobbiest, if they're a lot better than just a shop vac?

[tomzarbo]

Re: My 1st build thread

Nice job so far, Tom, especially on those pesky truncated woofer recesses!

TomZ

[tom_s]

Re: My 1st build thread

Thanks TomZ! I just finished setting the Hurricane nuts for the woofers. I took the advice that I had read long ago and gave them shot of Super Glue as I pulled them snug.

Rogoll- Yep, that's a Delta dust collector next to the saw. It's an older one that sits on a big cardboard drum. I just shove the 4" exhaust hose out the window and it clears the room pretty quickly. A 2" hose attached to my RO sander works surprisingly well!

[nick29498141]

Re: My 1st build thread

Thanks TomZ! I just finished setting the Hurricane nuts for the woofers. I took the advice that I had read long ago and gave them shot of Super Glue as I pulled them snug.

Rogoll- Yep, that's a Delta dust collector next to the saw. It's an older one that sits on a big cardboard drum. I just shove the 4" exhaust hose out the window and it clears the room pretty quickly. A 2" hose attached to my RO sander works surprisingly well!

Hurricane nuts, too?! You're going in ten-deep for your first build, good job!

NK

[tom_s]

Re: My 1st build thread

Ahhh, you give me too much credit. It's not my first build by a long shot, just my first build thread! Having had to drill out the screw bound up in a spinning hurricane nut, I now head the warnings of others who came before me! A little dribble of super glue for added insurance...;)

[tom_s]

Re: My 1st build thread

I didn't get nearly as much done today as I had hoped. It turns out that the round recessed terminal cups have changed over the years. They are just over .5mm larger than 10 years ago. As luck would have it, I used an old one (and I only have one of the old version!) to size the hole and recess for the flange. A little sanding on the new one brought it down enough to fit. Now I just need to make the recess deeper to account the foam seal that was not present on the old cups.

I also found out that I should have gone a little smaller on the through hole for the tweeter. You'll see how my screws wandered in one picture. I hope to fix this with some surplus metal donut thingies (I think that's the technical term:p) that have been hanging on my pegboard for years.

I glued up the port tube receivers and cut some Wally World mattress pad...errr, dampening material. I did stop at Lowes and buy 4 more 6" clamps and more paint for the baffles. I liked how my brother's turned out-They're the last photo here, so I'll use the same Hammered Finish paint on these too. Still a lot of work to go. I need to pick up some bolts for the baffle, but we are close to making some sound...I hope!