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  • Help Assembling Overnight Sensations Crossovers....

    full disclosure. i never put together a crossover before, so i need as much tutorials as possible.

    bought the OS kits, and almost done with the boxes and now need to start putting together the crossover parts.

    are there any schematics? what wires do you use? how you attach components to the board (glue?).

    thanks much!

  • #2
    Re: Help Assembling Overnight Sensations Crossovers....

    Pegboard and zipties with added glue for the inductors is the typical method.







    There are many ways to do it, but here is a method that will work for lots of them:

    http://techtalk.parts-express.com/blog.php?b=195


    ...and for reference the schematic of what is shown:


    Curt Campbell has his nodal analysis:
    http://speakerdesignworks.com/nodal_analysis.html

    Coil placement (noting 3-4" for air-cores is far enough away laying flat):
    http://www.troelsgravesen.dk/coils.htm

    Hope that helps,
    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


    • #3
      Re: Help Assembling Overnight Sensations Crossovers....

      Schematic is at http://www.sites.google.com/site/und...ightsensations

      I use speaker wire for internal wiring.

      Notice tweeter is reverse polarity.

      Comment


      • #4
        Re: Help Assembling Overnight Sensations Crossovers....

        thanks Wolf!

        where can i buy pegboard?

        do i need a solder and electrical wires?

        Comment


        • #5
          Re: Help Assembling Overnight Sensations Crossovers....

          There's a couple of suppliers of OS kits, different OS configurations (MT, MTM, MMTMM), some using Dayton and some HiVi tweeters. Which supplier/configuration/tweeter do you have, we can steer you in the *correct* direction.

          Comment


          • #6
            Re: Help Assembling Overnight Sensations Crossovers....

            Wolf's (and indeed most others) crossover boards look far prettier than anything I've ever done, but for simplicity's sake, I have just twisted leads together according to spec, soldered, and then just hot glued the whole mess to the bottom panel of the inside of the speaker. It ain't pretty, and with larger inductors you need a whole heap of glue, but it does work. Once they're built, you won't ever see the things again.

            You can get pegboard at Home Despot etc, usually in a much bigger panel than needed.

            You can get a cheap soldering iron and solder at Radio Shack, or order some from the fine folks here at PE if you don't mind waiting.

            Comment


            • #7
              Re: Help Assembling Overnight Sensations Crossovers....

              Originally posted by smokarz View Post
              thanks Wolf!

              where can i buy pegboard?

              do i need a solder and electrical wires?
              Any local hardware or big-box hardware will have it. Lowes, Menards, HD, take your pick. ~$5/sheet of 2' x 4'. I've gone through about 3-4 sheets of it over the projects I've done myself, so one will last you awhile.

              You need any typical 60/40 resin-core solder unless you want to go lead-free, and most use 16 or 18AWG solid-core wire to connect where leads don't reach. Most of the time it's preferred to attach component leads only and avoid more wire if possible, so layout can be critical.

              Hope that helps!
              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: Help Assembling Overnight Sensations Crossovers....

                Originally posted by rvsixer View Post
                There's a couple of suppliers of OS kits, different OS configurations (MT, MTM, MMTMM), some using Dayton and some HiVi tweeters. Which supplier/configuration/tweeter do you have, we can steer you in the *correct* direction.
                i have this kit.

                http://www.diysoundgroup.com/speaker...eaker-kit.html

                Comment


                • #9
                  Re: Help Assembling Overnight Sensations Crossovers....

                  Originally posted by smokarz View Post
                  The link provided on that page (and djg provided) are correct then:
                  https://sites.google.com/site/undefi...ightsensations

                  Comment


                  • #10
                    Re: Help Assembling Overnight Sensations Crossovers....

                    Originally posted by djg View Post
                    Schematic is at http://www.sites.google.com/site/und...ightsensations

                    I use speaker wire for internal wiring.

                    Notice tweeter is reverse polarity.
                    is this really true?

                    so + go to - on the tweeter?

                    Comment


                    • #11
                      Re: Help Assembling Overnight Sensations Crossovers....

                      Originally posted by smokarz View Post
                      is this really true?

                      so + go to - on the tweeter?
                      From xover, positive line goes to negative on tweeter- yes.

                      It's phasing, not necessarily + or -, but how the drivers relate after the xover phase additions.

                      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: Help Assembling Overnight Sensations Crossovers....

                        This is how I learned how to build a crossover.

                        http://www.speakerbuilder.net/web_fi...xo/xoconst.htm

                        About the only thing that's changed for me over time is that I now use zip ties instead of "goop" glue to hold the components down to the board. If you want permanent, however, then you can't beat Goop.
                        Isn't it about time we started answering rhetorical questions?

                        Paul Carmody's DIY Audio Projects
                        Twitter: @undefinition1

                        Comment


                        • #13
                          Re: Help Assembling Overnight Sensations Crossovers....

                          Hey smokarz, I just finished the OS's. I was in the same boat: first-time crossover build. (My only previous speaker build was some Pi 2's. With only a cap and an inductor, I guess that doesn't really count...)

                          Anyway, here's some photos and notes that might be helpful. Click for larger images.



                          I used perfboard from PE (#320-470) and some barrier strips (#090-844). (Maybe overkill with the barriers but I wanted everything to stay in place.) Zipties to hold down the inductors. Most component leads fit through the perf holes, but some (inductors) needed a little widening; I used an X-acto blade. (I was worried I'd mess up the component wiring and layout somehow, but it sounds good so I think I did alright? I hope someone will let me know if something looks out of place.)



                          Testing the crossover. I used cable nail-in clips (the kind that hold coax cable to the wall) as standoffs for the perfboard. The wires are 18 ga. solid core. I bent each connection back about 45 deg toward the board so they wouldn't obstruct anything. The leads were all twisted together underneath the perf, and then soldered once it all checked out.

                          I opted for the knock-in binding posts. I drilled .25" holes, but had to really whack at the first one to get it to seat tightly. For the rest I sanded out the holes a bit and they tapped in easier but still sealed tight. It seems like people have varying experiences with these; some have no problem with narrower holes while others have the same issue I did.

                          Hope this helps. I'm really happy with these speakers. Well balanced (to my ears) with solid bass that seems impossible from the physical size of the cabinets. Many thanks to Paul C. for the design and Erich for the great flat-pack kits.

                          (BTW is there a TT forum-member-of-the-year? I'd nominate Erich for all the selfless hard work he's put into helping us non-woodshop folk.)

                          Chris

                          Comment


                          • #14
                            Re: Help Assembling Overnight Sensations Crossovers....

                            Originally posted by rewind67 View Post

                            (btw Is There A Tt Forum-member-of-the-year? I'd Nominate Erich For All The Selfless Hard Work He's Put Into Helping Us Non-woodshop Folk.)

                            Chris
                            +1


                            .
                            “I cried because I had no shoes until I met a man who had no feet”

                            If we all did the things we are capable of doing, we would literally ASTOUND ourselves - Thomas A. Edison

                            Some people collect stamps, Imelda Marcos collected shoes. I collect speakers.:D

                            Comment


                            • #15
                              Re: Help Assembling Overnight Sensations Crossovers....

                              Check out Post #7 in this thread:

                              http://72.9.35.76/showthread.php?t=221819

                              The crossovers I made for my Overnight's are separated them into a high-pass and low-pass section, and I didn't use any boards.

                              Comment

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