MiniByzy (Mini Byzantium) Build Thread

[r-carpenter]

Re: MiniByzy (Mini Byzantium) Build Thread

Six, 1/8" HDF boards with epoxy in between each layer. Amazingly strong when cured. Panels are under a LOT of tension as they cure, resulting in a type of pre-stressed panel at the end. It's the hardest cabinet material I've ever encountered that wasn't marble or metal. Think, bowling ball, and you get an idea of how hard and stiff the result is.

French developed this technique in the beginning of 20th century. Curved doors on Deco cabinets. They also used scoring which is not as good of a solution for a speaker wall. I 100 years old see panels that are laminated just as your friend did and they are in a great shape. It's really a good way of doing curved wall enclosure. I usually use vacuum set up. Is he clamping cold?

[Pete Schumacher]

Re: MiniByzy (Mini Byzantium) Build Thread

French developed this technique in the beginning of 20th century. Curved doors on Deco cabinets. They also used scoring which is not as good of a solution for a speaker wall. I 100 years old see panels that are laminated just as your friend did and they are in a great shape. It's really a good way of doing curved wall enclosure. I usually use vacuum set up. Is he clamping cold?

Simple clamps at the edges of the form, using the natural tendency of the panels to snap back to create all the pressure during the cure of the marine grade epoxy. There's a LOT of spring tension in those 6 panels. Ed lets them cure for at least 8 hours.

[r-carpenter]

Re: MiniByzy (Mini Byzantium) Build Thread

Nice!
I do unibond, heat (about 165f) and vacuum for 4 hours. I also fabricate the "mother" for vacuum clamping.

[Pete Schumacher]

Re: MiniByzy (Mini Byzantium) Build Thread

Progress continues rapidly. He's got the left side ready, and almost done on the right. You can clearly see the epoxy layers now that it's been sanded smooth.

[gvimhoof]

Re: MiniByzy (Mini Byzantium) Build Thread

Woof!

[DjDisturbed]

Re: MiniByzy (Mini Byzantium) Build Thread

Those look like they will be another awesome looking speaker. And those drivers should sound great paired together. I would like to have those drivers to make a TM cabinet myself.
It will be interesting to see the waveguide for the tweeter made into the baffle with that piece of wood he picked out.

[Pete Schumacher]

Re: MiniByzy (Mini Byzantium) Build Thread

Been a while since an update. Ed's been taking some vacations, and building some jigs to fabricate perfect clones so the set is truly matching.

Below are pictures of a less than perfect attempt, with a single layer of HDF applied to the back. Ed used those to measure the volume with sand. (Came it at 1.25 cubic feet.) Get a nice sense of the lines from these two shots.

Turns out that we'll probably stick the Vifa NE225W in there instead of the Usher. Cross it between 1000 and 1200 to the waveguide loaded RS28F. But now that we know the volume, there are numerous options for woofers, including the Discovery and SB Acoustics models.

I've been told to expect the cabinets fairly soon. Looking forward to it for sure.

Ed described the second picture as reminiscent of Beyonce. :D ;)

[Pete Schumacher]

Re: MiniByzy (Mini Byzantium) Build Thread

Here's the pair on their jigs. Ed says he's gotten all four sides within 1mm of each other, all the way round.

[rmeinke]

Re: MiniByzy (Mini Byzantium) Build Thread

Man Pete, these are just crazy amazing. Hard looking at simple boxes after seeing these bad boys! Watching this one closely...

[Pete Schumacher]

Re: MiniByzy (Mini Byzantium) Build Thread

Here's a close up of the matching sides, showing Ed's spacer for holding the sides at the correct separation while the epoxy sets.

I like the looks of those smooth, and well defined panel edges, with the epoxy layers showing through.

I can't wait to see what he comes up with for applying the backs.

[rmeinke]

Re: MiniByzy (Mini Byzantium) Build Thread

Flipping amazing...

[Pete Schumacher]

Re: MiniByzy (Mini Byzantium) Build Thread

A pair of clones, ready for the backs to be applied.

[davepellegrene]

Re: MiniByzy (Mini Byzantium) Build Thread

Love to watch Ed's builds. What a craftsman! I'm guessing he's having a lot of fun too.
Looking a few posts back were the back is applied. It looks like it is just one layer of hardboard. Is that the final cabinet? Looks like he started filling the seams so I assume it's a finished cabinet. If so I would think with the sides being so many layers that the back would be multiple layers as well.
Just curious.

Dave

[Pete Schumacher]

Re: MiniByzy (Mini Byzantium) Build Thread

Love to watch Ed's builds. What a craftsman! I'm guessing he's having a lot of fun too.
Looking a few posts back were the back is applied. It looks like it is just one layer of hardboard. Is that the final cabinet? Looks like he started filling the seams so I assume it's a finished cabinet. If so I would think with the sides being so many layers that the back would be multiple layers as well.
Just curious.

Dave

That one with the single layer of HDF applied to the back was a test mule, used for determining the volume of the enclosure. There was a bit of a flaw in one of the side panels, so he used a pin-nailer to put that back piece in place. He's going to use 6 layers, for a .75" thick back, just like the sides. But I think he's going to apply the backs without a pin nailer. I'm hoping some pics show up later on with that process being documented like he's done the rest. I'm getting real excited to begin testing with these. And I know Ed's really pumped up as well.

[davepellegrene]

Re: MiniByzy (Mini Byzantium) Build Thread

That one with the single layer of HDF applied to the back was a test mule, used for determining the volume of the enclosure. There was a bit of a flaw in one of the side panels, so he used a pin-nailer to put that back piece in place. He's going to use 6 layers, for a .75" thick back, just like the sides. But I think he's going to apply the backs without a pin nailer. I'm hoping some pics show up later on with that process being documented like he's done the rest. I'm getting real excited to begin testing with these. And I know Ed's really pumped up as well.

Ok, that makes sense. I did see in the one pic were it looked like the one panel cracked as he was wrapping it around. Looks like it's going to take a lot of support to wrap them that tight. I'm sure Ed will handle it. Maybe a reason to build another Jig.

Dave