18” down-firing EGG shaped sub build… - AVS Forum
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post #1 of 108 Old 04-29-2010, 09:11 AM - Thread Starter
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I ordered the driver, bought the wood, and will be starting the cutting this weekend. This will be a bit of an unusual build. Some will say that it will be ugly, but the wife has given her stamp of approval, and more importantly, I like it. It should be a nice step up from my current Titanic III 15”.

The driver will be a Maelstrom-18".
Amp will be a Behringer EP4000.
EQ will be a Behringer DSP1124P Feedback Destroyer.
Using ¾” MDF to make a 5.75 cubic foot sealed enclosure (internal).
Walls to start at 2” thick and then be sanded down to maybe 1&3/4.

I don’t have any graphics software but have managed to put something together with Excel & Word. Here is a cross section of what it should end up looking like. It will be 30” wide by 35.25” high. I have noticed that with Word, dimensions will be skewed from one computer to the next depending on settings. The width should be 85% of the height, so if you want to see it scaled properly, you may need to do some stretching of it.

 

Eggbuild diagram 4-27-101.doc 95k . file

My Maelstrom-18" EGG build.
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post #2 of 108 Old 05-05-2010, 07:44 AM - Thread Starter
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A few people on another site were saying that I needed more bracing. Here is the new design. Anyone feel like helping me get this monster up the stairs when it's finished?

Cutting begain last weekend. There were a lot of setbacks at first, but now it's moving along well. I have 15 rings cut and the rest have all been drawn out. Just need to connect the dots with the jig saw and then I can start stacking.
LL

My Maelstrom-18" EGG build.
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post #3 of 108 Old 05-05-2010, 08:12 AM
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Everyone's getting into the stacked ring builds. I cant wait to see it finished.

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Even i, the genius, only vaguely understand what i am saying here.
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post #4 of 108 Old 05-05-2010, 08:31 AM - Thread Starter
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I guess you could say that we've been thinking outside the box.

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post #5 of 108 Old 05-05-2010, 10:38 AM
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Good luck with this. That's a lot of work. Prepare!


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post #6 of 108 Old 05-05-2010, 11:11 AM
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the egg idea is pretty neat.

are you planning to knock the corners off all the horizontal pieces or fill in the dips with something?

an alternative solution could be to wrap the whole thing in fiberglass.

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post #7 of 108 Old 05-05-2010, 11:38 AM
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Quote:
Originally Posted by LTD02 View Post

the egg idea is pretty neat.

are you planning to knock the corners off all the horizontal pieces or fill in the dips with something?

an alternative solution could be to wrap the whole thing in fiberglass.

Or Great Stuff foam.

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post #8 of 108 Old 05-05-2010, 11:48 AM - Thread Starter
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Quote:
Originally Posted by LTD02 View Post

the egg idea is pretty neat.

are you planning to knock the corners off all the horizontal pieces or fill in the dips with something?

an alternative solution could be to wrap the whole thing in fiberglass.

Thanks,

I was in an art gallery and noticed a lot of egg shaped "art". Seemed like a good plan.

My plan is to be sanding them off for the next 2-3 weeks, (or is that years?)
I don't have any experience with fiberglass (or bondo). Not sure how much easier or harder that is.

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post #9 of 108 Old 05-05-2010, 11:52 AM - Thread Starter
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Quote:
Originally Posted by Ricci View Post

Good luck with this. That's a lot of work. Prepare!

Thanks,

That's for sure. Good thing I'm not in a hurry.

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post #10 of 108 Old 05-18-2010, 02:35 PM - Thread Starter
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I have been on vacation for a bit, so I'm behind on picture posting. I did get a lot done though. Here are a few to catch everyone up.

First, all the scrap wood left over.
LL

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post #11 of 108 Old 05-18-2010, 02:35 PM - Thread Starter
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Then the rings that will be put to work.
LL

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post #12 of 108 Old 05-18-2010, 02:37 PM - Thread Starter
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Time for inventory. Can't start if all the pieces are not available.
LL

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post #13 of 108 Old 05-18-2010, 02:38 PM - Thread Starter
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Slapping a few pieces together now. The bracing looks good.
LL

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post #14 of 108 Old 05-18-2010, 02:39 PM - Thread Starter
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Half an egg is better than none?
LL

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post #15 of 108 Old 05-18-2010, 02:39 PM - Thread Starter
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Stuff that baby!
LL

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post #16 of 108 Old 05-18-2010, 02:41 PM - Thread Starter
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It's starting to take shape. It's looking big, but I made room for the binding posts.
LL
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post #17 of 108 Old 05-18-2010, 02:42 PM
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Shouldn't be too bad to sand it down if you have a good belt sander and some aggressive belts. Use a dust mask. Hook a shop vacuum to the belt sander dust port.

Might be a cool idea to build a "potters wheel" with a big lazy Susan bearing so you can let the egg spin as you grind it down with the belt sander. Might get more consistent profile that way.

[I posted this before I realized the sanding part was done]

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post #18 of 108 Old 05-18-2010, 02:44 PM - Thread Starter
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It looks beter sanded.
This is the first coat of China Red. It looks more orange to me. The next coat id Red Oak. It's starting to look more like the Piano Rosewood that I want it to match. Once it dries it will get a coat of Red Mahogany and then a bunch of clear-coats.
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post #19 of 108 Old 05-18-2010, 02:47 PM - Thread Starter
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Quote:
Originally Posted by petew View Post

Shouldn't be too bad to sand it down if you have a good belt sander and some aggressive belts. Use a dust mask. Hook a shop vacuum to the belt sander dust port.

Might be a cool idea to build a "potters wheel" with a big lazy Susan bearing so you can let the egg spin as you grind it down with the belt sander. Might get more consistent profile that way.

A BIG potter's wheel huh? Maybe next time.

I did use a belt sander though. Took the better part of a day to hit it with 40 grit, 80 and then 120. After each primer and paint coats it gets hit with 220.

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post #20 of 108 Old 05-18-2010, 04:06 PM
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Very cool design! I love it!
Were you able to do all your cutting with a router on a circle jig?

My Maelstrom 21" curved box build

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post #21 of 108 Old 05-18-2010, 05:15 PM
 
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Looks good. Takes lots of patience to build a sub like this.
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post #22 of 108 Old 05-18-2010, 05:20 PM
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looks awesome!
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post #23 of 108 Old 05-18-2010, 06:20 PM - Thread Starter
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Quote:
Originally Posted by corock View Post

Very cool design! I love it!
Were you able to do all your cutting with a router on a circle jig?

Thanks,

Much like you, I tried the router first but ended up with the jigsaw. I saw that you cut your face-plate using the same attachment I picked up for circles. It did a fair job for me. I'm not the perfectionist you are, but it still came out OK.

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post #24 of 108 Old 05-18-2010, 07:43 PM
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Wow. Very cool.
Looks like some ancient religious object.
You could put some figures on it like a Grecian Urn.
I'm guessing it's very strong and inert.

 

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post #25 of 108 Old 05-18-2010, 07:56 PM
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I'm curious how you came up with the correct size/shape of an egg before you divided it into your 3/4" mdf sections. I mean, how did you know how much to increase or decrease each diameter to get the perfect egg shape in the end?

Great build.


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post #26 of 108 Old 05-18-2010, 11:44 PM
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You've given me an idea for my next build. Here's the prototype...


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post #27 of 108 Old 05-19-2010, 04:49 AM
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Quote:
Originally Posted by Gmichael2 View Post

Time for inventory. Can't start if all the pieces are not available.

That is pretty much the coolest pic showing everything before the build.

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post #28 of 108 Old 05-19-2010, 06:31 AM - Thread Starter
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Quote:
Originally Posted by Milt99 View Post

Wow. Very cool.
Looks like some ancient religious object.
You could put some figures on it like a Grecian Urn.
I'm guessing it's very strong and inert.

Strong like bull. It weighs over 150 pounds without the driver. Lots of bracing and packed half full with dampening. Figure the shape, and it's about as inert as you can get without going IB.

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post #29 of 108 Old 05-19-2010, 06:45 AM - Thread Starter
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Quote:
Originally Posted by Erich H View Post

I'm curious how you came up with the correct size/shape of an egg before you divided it into your 3/4" mdf sections. I mean, how did you know how much to increase or decrease each diameter to get the perfect egg shape in the end?

Great build.

I started with drawing the shape on graph paper (each box representing 0.75"). After a few tries, I got about what I wanted. Then I measured what I drew and put it into an Excel spread sheet. I graphed the numbers and added trend lines. Then I fudged the numbers to all come out matching the trend lines.
Then I took each radius and subtracted the next one to get a difference. Then subtracted each difference from the next to get a trend for the delta. This was all just done to check what Excel had given me. After a little tweeking, I was ready. Now I knew all the ring sizes needed. It took a while to figure out how to get all the rings I needed out of as few sheets of wood as possible. By making several of the rings as half rings to be glued together, I was able to cut everything from 4 sheets of MDF instead of 7. With MDF costing $32 a sheet now, that's a fair savings. (My plan was to use plywood instead of MDF before all the prices of wood shot up)

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post #30 of 108 Old 05-19-2010, 06:48 AM - Thread Starter
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Quote:
Originally Posted by corock View Post

You've given me an idea for my next build. Here's the prototype...


Where does the driver go? Is that an "almost infinate baffle"?
On another note. Your house must be much bigger than mine!

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