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My Latest Build Thread "Sonus Project"

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  • My Latest Build Thread "Sonus Project"

    Well fathers day is the day I started my Sonus project. I rough cut all the internal braces and ribs. I figures I would post the photo of my dirty shop for all the guys who goof on how clean it usually is.


    My first template was hardboard but that did not last. I decided to use that to make a 3/4 MDF template. it worked much better. For the record, this part alone produced 7 gallons on dust in my vac...
    Attached Files
    Last edited by mgrabow; 10-11-2010, 12:58 PM. Reason: spelling
    Mark


    http://www.diy-ny.com

  • #2
    Re: My Latest Build Thres "Sonus Project"

    Originally posted by mgrabow View Post
    Well fathers day is the day I started my Sonus project. I rough cut all the internal braces and ribs. I figures I would post the photo of my dirty shop for all the guys who goof on how clean it usually is.


    My first template was hardboard but that did not last. I decided to use that to make a 3/4 MDF template. it worked much better. For the record, this part alone produced 7 gallons on dust in my vac...
    Not so much goofing as jealous. I can never keep my shop clean. Its amazing the dust created from a build. Its usually more then the final product in volume.
    This will be a fun build to watch progress. It will definitely be a lot of work.
    Dave
    http://www.pellegreneacoustics.com/

    Trench Seam Method for MDF
    https://picasaweb.google.com/101632266659473725850

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    • #3
      Re: My Latest Build Thread "Sonus Project"

      I fat fingered the title... Thread... not Thres


      Figured out how to fix it...thanks
      Last edited by mgrabow; 06-24-2010, 09:27 PM. Reason: correction
      Mark


      http://www.diy-ny.com

      Comment


      • #4
        The right tool for the job...

        Today I was drilling the large holes in by braces... There was a day when I sat around for hours burning (I mean cutting) holes in MDF with a hole saw. Well I purchased a carbide tipped hole saw. The Milwaukee "Big Hawg".... Wow... 15 seconds per hole with a drill press. perfectly smooth with no burning. I will never buy another non-carbide tipped hole saw again...
        Mark


        http://www.diy-ny.com

        Comment


        • #5
          Re: The right tool for the job...

          Originally posted by mgrabow View Post
          Today I was drilling the large holes in by braces... There was a day when I sat around for hours burning (I mean cutting) holes in MDF with a hole saw. Well I purchased a carbide tipped hole saw. The Milwaukee "Big Hawg".... Wow... 15 seconds per hole with a drill press. perfectly smooth with no burning. I will never buy another non-carbide tipped hole saw again...
          They will eat through nails really easy too. I've got some that are 20 plus years old and they still cut great.
          Dave
          http://www.pellegreneacoustics.com/

          Trench Seam Method for MDF
          https://picasaweb.google.com/101632266659473725850

          Comment


          • #6
            Re: My Latest Build Thres "Sonus Project"

            Originally posted by mgrabow View Post
            I fat fingered the title... Thread... not Thres
            You can edit the title.
            "Socialism is a philosophy of failure, the creed of ignorance, and the gospel of envy." --Winston Churchill

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            • #7
              Re: My Latest Build Thread "Sonus Project"

              Originally posted by robwest View Post
              You can edit the title.
              Thanks, I didnt see the advanced button...
              Last edited by mgrabow; 06-24-2010, 09:27 PM. Reason: spelling
              Mark


              http://www.diy-ny.com

              Comment


              • #8
                Re: My Latest Build Thread "Sonus Project"

                Finished the braces today. Squared off the corners by clamping them all together and running them over a dato blade. 5 minutes with the belt sander to match all the edges perfectly and its ready to assemble the skeleton...
                Attached Files
                Last edited by mgrabow; 07-25-2010, 10:03 PM. Reason: spelling
                Mark


                http://www.diy-ny.com

                Comment


                • #9
                  Re: My Latest Build Thres "Sonus Project"

                  i too used the belt sander to perfect the pieces. nice build. keep the pics comming.
                  Last edited by [email protected]; 07-11-2010, 10:59 PM. Reason: oops
                  " To me, the soundstage presentation is more about phase and distortion and less about size. However, when you talk about bass extension, there's no replacement for displacement". Tyger23. 4.2015

                  Quote Originally Posted by hongrn. Oct 2014
                  Do you realize that being an American is like winning the biggest jackpot ever??

                  http://www.midwestaudioclub.com/spot...owell-simpson/
                  http://s413.photobucket.com/albums/pp216/arlis/

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                  • #10
                    Re: My Latest Build Thread "Sonus Project"

                    As always I think I am ready to put it all together and there is still more to be done. I finished rounding odd all the edges with a roundover bit. I also needed to make what I call the "rib Cage"... So I needed to break out the "Big Hawg' bits and drill some more holes... Just an FYI for anyone using those Big Hawg bits on a drill press. make sure the work piece is clamped down well and you may need to stop it at the bottom of the hole before raising the bit. You may het some chatter from those huge carbide teeth...
                    Attached Files
                    Mark


                    http://www.diy-ny.com

                    Comment


                    • #11
                      Re: My Latest Build Thres "Sonus Project"

                      Wow! Miss a day and you miss a lot! Actually, I have missed about a month and a half with work being very busy and then a vacation with little to no affordable internet access.

                      Your build is looking very nice so far! You internals may end up looking better than my externals!! Where did you buy your Big Hawgs? What's the plan of attack for the curved sides and baffles? Curved sides and individual interchangeable baffle sections will be my next challenge when work slows down.

                      Tom
                      Co-conspirator in the development of the "CR Gnarly Fidelity Reduction Unit" - Registered Trademark, Patent Pending.

                      Comment


                      • #12
                        Re: My Latest Build Thres "Sonus Project"

                        hurry up man! It needs to be finished for Aug 14th. I am pushing my Paper Stone. :D
                        http://www.diy-ny.com/

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                        • #13
                          Re: My Latest Build Thread "Sonus Project"

                          There are lost of places to get the Big Hawgs. Norther Tools.com had the kit for about $168 or something like that... No more burning MDF smell for me...


                          Well if you measure how much of a bend the sides of my cabinet are, you will only need to bend the panel about 1 inch... The depth of the cabinets are about 13 inches (side panels...) In Europe they can get 1/8 inch MDF. I have 1/4 here on Long Island. I can bend it about an inch over my knee so I think I should be fine...


                          I am going to do a clamp test first by clamping it along the front edge using a piece of angle iron or maybe some oak...Use a little two face tape under the angle iron or oak to keep it managable...Then using some ratchet straps, I will bend it over and see if it goes smoothly... If it does I will remove it and add the glue and go for it... I was debating on gluing the front edge and clamping it till it dries. Then adding glue to the rest. I am afraid of shifting and slipping even when clamped. The original builder used stables on the leading edge. I don't think my staple gin will go through 1/4 inch mdf... I may even get a cheap air stapler...


                          You can see the original Masterpiece at:
                          http://matrixhifi.com/foro/viewtopic...ght=sonus+pazo
                          This guy did an amazing job. I wish I had access to a CNC Machine (and the time to create the CAD files)


                          These two photos are from the original builder...
                          Attached Files
                          Last edited by mgrabow; 07-25-2010, 10:02 PM. Reason: missing scentence
                          Mark


                          http://www.diy-ny.com

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                          • #14
                            Re: My Latest Build Thread "Sonus Project"

                            Originally posted by r-carpenter View Post
                            hurry up man! It needs to be finished for Aug 14th. I am pushing my Paper Stone. :D

                            I wish...I may still need to get rid of my last build to pay for the remaining components of this one...
                            Last edited by mgrabow; 07-25-2010, 10:02 PM. Reason: spelling
                            Mark


                            http://www.diy-ny.com

                            Comment


                            • #15
                              Re: My Latest Build Thres "Sonus Project"

                              These look nice. I want to try my hand at a curved speaker someday. Looking forward to see the finished product. Keep it up!

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