Super THT build thread - AVS Forum
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post #1 of 243 Old 11-14-2009, 10:17 PM - Thread Starter
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Ok, so I am building a Tuba Home Theater subwoofer using the plans from Billfitzmaurice. I have maxmercy and myn to thank for their great advice and especially myn for his VERY detailed build thread! This build thread will not be anywhere near as detailed because I am working with my friend Joe who is a Professional woodworker with a degree in Furniture design = he is a woodworking genius! So since he is such a good wood worker, he works much faster than I would if I tried to do this build myself, so their will be very few brakes to actually sit back and take pictures.
I am building with Joe's help the THT 30" version because my wife is amazing and is letting me build one of the larger versions of this impressive subwoofer.
Here is a pic of the Dayton woofer I am using, it is the one that Bill recommends in the plans.

Here is Joe getting started on making cuts on his beautiful table saw, the magical tool that makes this build SOOOOOO much easier than with a circular saw!

Here is Joe doing the plunge cuts for the woofer access panel.

Here are all the major pieces minus bracing and deflectors

More to come in the coming week.
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post #2 of 243 Old 11-15-2009, 12:42 AM
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very cool.

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post #3 of 243 Old 11-15-2009, 06:55 AM
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Nice saw. Is that Baltic Birch? I am very happy with my Fitz Table Tuba, dual 8
" variety. The THT should rock.
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post #4 of 243 Old 11-15-2009, 08:15 AM - Thread Starter
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It is Birch and is the best looking plywood I have ever seen!
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post #5 of 243 Old 11-15-2009, 08:49 AM
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Quote:
Originally Posted by superedge88 View Post

It is Birch and is the best looking plywood I have ever seen!

As far as I'm concerned, void free plywood like this is the only way to go around here. My lungs won't stand for MDF dust, and the finished product ends up being lighter.

Looking forward to seeing how this one turns out too. I'm slowly getting to the point of deciding that if I want to learn horn design, I should start with building something already proven awesome and learn by doing. It also doesn't hurt that Solen carries the driver for us Canadians without having to deal with ordering PE stuff across the border.
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post #6 of 243 Old 11-15-2009, 10:11 AM
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Nice! 30" FTW!

That birch looks great. You going to finish it with stain or ?

Looking forward to watching this build. If I can be of any help, let me know.
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post #7 of 243 Old 11-15-2009, 12:37 PM
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Quote:
Originally Posted by superedge88 View Post

Here is Joe doing the plunge cuts for the woofer access panel.

He'd get a far more accurate and straight cut by using a guideboard or saw sled. It would be safer too. Fingers and saw blades are a bad combination.

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post #8 of 243 Old 11-15-2009, 01:24 PM
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Sweet! But what's the freaky-looking thing in the corner?

In terms of LFE, size does matter!
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post #9 of 243 Old 11-15-2009, 01:40 PM
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its a cat

If at first you dont succeed , get a bigger hammer !
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post #10 of 243 Old 11-15-2009, 02:14 PM - Thread Starter
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Quote:
Originally Posted by Bill Fitzmaurice View Post

He'd get a far more accurate and straight cut by using a guideboard or saw sled. It would be safer too. Fingers and saw blades are a bad combination.

I don't tell Joe what to do, he's the master wood worker. Cuts turned out great. Thanks for the heads up though.
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post #11 of 243 Old 11-15-2009, 02:14 PM - Thread Starter
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Sweet! But what's the freaky-looking thing in the corner?

He's my sphynx cat.
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post #12 of 243 Old 11-15-2009, 02:17 PM
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hehe. Cats LOVE horn's. I'll let MaxMercy tell his story about his cats and what he did to keep them out of the throat of the horn .
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post #13 of 243 Old 11-15-2009, 04:14 PM
 
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Quote:
Originally Posted by Bill Fitzmaurice View Post

He'd get a far more accurate and straight cut by using a guideboard or saw sled. It would be safer too. Fingers and saw blades are a bad combination.

If that saw catches it will not run toward his hand. It is a worm-drive saw. The blade turns the opposite direction from a regular skil-saw. Nice strong saw, but they are heavy.
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post #14 of 243 Old 11-15-2009, 04:25 PM
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Quote:
Originally Posted by mjg100 View Post

If that saw catches it will not run toward his hand. It is a worm-drive saw. The blade turns the opposite direction from a regular skil-saw. Nice strong saw, but they are heavy.

Regardless, Bill's right. Those plunge cuts need to be as straight as possible and a guide board would guarantee the straight cut. Keep in mind that the access panel cover is cut out and used from those 4 cuts as well as the opening for the driver from the side panel. Very very important cuts .
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post #15 of 243 Old 11-15-2009, 05:37 PM
 
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Quote:
Originally Posted by mynym View Post

Regardless, Bill's right. Those plunge cuts need to be as straight as possible and a guide board would guarantee the straight cut. Keep in mind that the access panel cover is cut out and used from those 4 cuts as well as the opening for the driver from the side panel. Very very important cuts .

Not arguing that at all. All I was pointing out was his fingers toward the front of that saw are not in danger. That saw will kick back not forward. I doubt that many here are familiar with a worm-drive.
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post #16 of 243 Old 11-15-2009, 05:58 PM - Thread Starter
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Quote:
Originally Posted by mynym View Post

Regardless, Bill's right. Those plunge cuts need to be as straight as possible and a guide board would guarantee the straight cut. Keep in mind that the access panel cover is cut out and used from those 4 cuts as well as the opening for the driver from the side panel. Very very important cuts .

I fail to see why they have to be as straight as possible, in my understanding the seal is actually made with the trim pieces that the access panel actually sits down on to. We are actually making a panel to exact dimensions as the hole, not using the wood that was cut out when making the access hole. We are designing fake door panels to go over the access panel, we are making this THT into a piece of furniture that will look like an end table... a very big end table.
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post #17 of 243 Old 11-15-2009, 06:29 PM
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Quote:
Originally Posted by superedge88 View Post

I fail to see why they have to be as straight as possible, in my understanding the seal is actually made with the trim pieces that the access panel actually sits down on to. We are actually making a panel to exact dimensions as the hole, not using the wood that was cut out when making the access hole. We are designing fake door panels to go over the access panel, we are making this THT into a piece of furniture that will look like an end table... a very big end table.

The access panel flanges sit flush against the interior panels 1, 2 ,3 and 4. As long as those 4 panels are flush against the edges of the access hole the flanges should be golden. If though the access hole is cut sloppy there may be some over/under hang. Sorry I should have explained it better.

This may explain it better:



MaxMercy stained his THT. It turned out really well. Are you going to add any additional flare to the outside of the THT to make it look an end table?
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post #18 of 243 Old 11-15-2009, 07:29 PM - Thread Starter
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I see what you mean, I will make sure that things are within the tight tolerances. The plan so far is to add crown molding along the top and bottom edge, use granite tile for the top, make fake doors and a drawer to cover the access panel (but still be removable) with brushed stainless steel handles and paint the whole THT a dark charcoal gray. I will draw up a sketch of what I want it to look like and post it.
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post #19 of 243 Old 11-16-2009, 04:44 AM
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Quote:
Originally Posted by superedge88 View Post

I see what you mean, I will make sure that things are within the tight tolerances. The plan so far is to add crown molding along the top and bottom edge, use granite tile for the top, make fake doors and a drawer to cover the access panel (but still be removable) with brushed stainless steel handles and paint the whole THT a dark charcoal gray. I will draw up a sketch of what I want it to look like and post it.

WAF +10. Very cool
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post #20 of 243 Old 11-16-2009, 06:04 PM
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This looks like a cool build off to a good start!

But that cat reminds me of Pet Cemetary.
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post #21 of 243 Old 11-18-2009, 03:50 PM - Thread Starter
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I received my speaker terminals in the mail for about 6 bucks shipped! Gonna get back to work on the build in the next couple of evenings.
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post #22 of 243 Old 11-18-2009, 08:51 PM
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Quote:
Originally Posted by Rightbrained View Post

its a cat

that is an awesome lookin sphynx!
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post #23 of 243 Old 11-18-2009, 09:31 PM - Thread Starter
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that is an awesome lookin sphynx!

Thanks, that's very nice of you to say! I have three sphynx cats, they are the most personable cat breed you can find because from a very young age they learn that they have to come to humans for warmth!
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post #24 of 243 Old 11-18-2009, 10:23 PM
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Quote:
Originally Posted by superedge88 View Post

Thanks, that's very nice of you to say! I have three sphynx cats, they are the most personable cat breed you can find because from a very young age they learn that they have to come to humans for warmth!

are they rather spendy? how well "trained" rather domesticated? I'll be moving into my own home soon, so no more "no pets!" and that cat is beautiful!

just to stay "on topic" more pics! I know, you've got a builder and not much time to snap away, just had to say it
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post #25 of 243 Old 11-19-2009, 08:46 AM
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Nice to see another horn build! I have a worm drive saw, but didn't realize they turned the opposite way. At any rate they are heavy, but it's nice to be able to see what you're cutting without having to lean over the saw.
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post #26 of 243 Old 11-19-2009, 01:05 PM - Thread Starter
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SO I am debating on what amplifier to get now, was sold on the Oaudio 500 watt, but now with everyone saying how efficient this subwoofer is should I just go ahead and get the Oaudio 300 watt version?
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post #27 of 243 Old 11-19-2009, 03:05 PM
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SO I am debating on what amplifier to get now, was sold on the Oaudio 500 watt, but now with everyone saying how efficient this subwoofer is should I just go ahead and get the Oaudio 300 watt version?

It's unlikely you'll ever use more than 100 watts. 300 would have plenty of headroom.

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post #28 of 243 Old 12-04-2009, 10:34 AM - Thread Starter
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Here is a pic of the start of the horn being built, I am so glad that Joe is helping me out with this build, he is a woodworker, I am definitely not!
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post #29 of 243 Old 12-04-2009, 10:36 AM - Thread Starter
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Not really that great of a pic, but here it is anyways.
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post #30 of 243 Old 12-04-2009, 10:38 AM - Thread Starter
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Here is a picture of a dork next to the project (me) to give scale, this thing is HUGE!!! (that's what she said)
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