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Old 02-21-2012, 02:49 PM - Thread Starter
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I am about to begin on a pair of cabinets like my Howitzers, for a friend.
These will be a little shorter, as he wants to install two NHT 10s per cabinet, vs. the three per cab that I used.
At least I can re-use the same curved forms used in the Howitzer build.
My friend will do all the finish work. I am just building the cabs.
Stay tuned.

"Still, a man hears what he wants to hear and disregards the rest." --Paul Simon The Boxer
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Old 02-21-2012, 02:58 PM
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Tuned in, thusly!
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Old 02-21-2012, 06:08 PM
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Subsribed. Of course.

JSS
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Old 02-21-2012, 06:58 PM
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Old 02-21-2012, 08:32 PM
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SUBscribed! Pun fully intended. I have decided to invite Orville Redenbacher over so I can have a truck load of popcorn!!

I think I know who PI is building these for and holy COW is that guy gonna love them!!

A bigger hammer is only better until you hit your thumb with it.
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Old 02-21-2012, 08:33 PM
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Yay! New PI build, always enjoy these for their sheer excellence.

 

Originally Posted by Bill Fitzmaurice:
It's also the very sort of Voodoo Engineering that should never be done.

 

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Old 02-21-2012, 08:40 PM
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Old 02-21-2012, 08:44 PM
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Quote:
Originally Posted by PassingInterest View Post

I am about to begin on a pair of cabinets like my Howitzers, for a friend.

Yes!


Quote:
Originally Posted by PassingInterest View Post

My friend will do all the finish work. I am just building the cabs.

Awww

Subbed
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Old 02-22-2012, 09:28 AM
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Awesome.
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Old 02-22-2012, 01:25 PM
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Count me in...

Chris

"It hurts to admit when you make mistakes - but when they are big enough, the pain only lasts a second."
--Despair, Inc. "Regret"

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Old 02-22-2012, 04:14 PM - Thread Starter
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I meant to take more pictures.
Assembling the frame went really fast, because I borrowed some Howitzer parts. I'll replace them later.

In the background, you can see a pair of no-longer-available NHT VR3s that I'm finally getting around to finishing.

There's more fun ahead, so stay tuned.


"Still, a man hears what he wants to hear and disregards the rest." --Paul Simon The Boxer
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Old 02-22-2012, 08:30 PM
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im jealous of your large collection of clamps in the background!!!
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Old 02-23-2012, 02:20 PM - Thread Starter
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Thanks for all the encouragement, guys.
I was in a hurry yesterday when I posted and forgot to say thanks.

Today was a gluing and clamping frenzy, as I did all four layers per side on both sides of one Mini-Gun cab--all at once!

I began by spreading glue on the frame and let it dry while I cut the 1/4" MDF to form the curved sides. A fan helped to speed the glue drying.




I stacked some cardboard on the workbench, so the 1/4" MDF 49"x97" sheets would be supported during the cut down the middle and to protect the workbench.




Set the cut-depth. Clamps hold two sheets together during the cut. I later realized that I need to cut a third sheet to have enough for the second cab. I'll do that tomorrow.




Remember to protect your eyes, ears and lungs.




After that, it is easy to cut to size on the table saw.




In the interest of frugality, the inner and outer panels are single, full size pieces and the two inner layers will be pieced together from two pieces, with the joint staggered from one layer to the next.




Let the gluing and clamping frenzy begin.




On your mark, get set...




Go!




I got faster as I went along.




As far as I'm concerned, if the clamps aren't bowed, I'm not using enough pressure. But this was funny enough to share with you fine folks here at AVS. This 3/4" Black Pipe (inside diameter) had a weak weld joint, which began to give way under pressure. I replaced it after I took this shot.




I have a Curvomatic on the way and I am excited about trying it, because this Howitzer form can do only one curve and it is bulky and heavy. It has one use only. That is it's limitation. The Curvomatic is limited by my imagination. I think Big Jim can help there and I hope he opens up a user forum some day. The curvy possibilities are staggering. I know, I sound like a commercial, but I can't help being a little excited about it.


"Still, a man hears what he wants to hear and disregards the rest." --Paul Simon The Boxer
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Old 02-23-2012, 04:03 PM
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Looking good as always!
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Old 02-23-2012, 04:43 PM - Thread Starter
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Quote:
Originally Posted by audiovideoholic View Post

Looking good as always!

Thanks. I appreciate it.

Before I started gluing, I dry clamped a single 1/4" MDF panel on each side of the cabinet and found that it did not resist bending nearly as much as the Luan plywood I used in a previous build. I was sure I could do all four layers on both sides at once, as long as I moved fast enough to get it clamped before the glue dried. Just to be safe, I drizzled some extra glue in places before clamping all the way.

I haven't seen 1/4" MDF at Home Depot or Lowe's, but a local McCoy's lumber and hardware store stocks it, so it isn't special order. I don't believe I could bend 1/2" MDF as-is without kerf-cuts or perhaps a chemical treatment.

When I glue-up the next cabinet, I'll show you folks the easy way to do it, so you and I can both avoid the frenzied approach. It's so simple and obvious, but I didn't think of it until just this moment.

"Still, a man hears what he wants to hear and disregards the rest." --Paul Simon The Boxer
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Old 02-23-2012, 05:32 PM
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Quote:
Originally Posted by PassingInterest View Post

When I glue-up the next cabinet, I'll show you folks the easy way to do it, so you and I can both avoid the frenzied approach. It's so simple and obvious, but I didn't think of it until just this moment.

...and that's why I have not started building my curved cabinet yet. I am waiting for you to show me the easy way to do it!

Looking good so far, though I think you should have used more clamps just to make redzone jealous.

Chris

"It hurts to admit when you make mistakes - but when they are big enough, the pain only lasts a second."
--Despair, Inc. "Regret"

My AviaTrix TM Build
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Old 02-23-2012, 07:50 PM
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I am 2 days behind on a PI build

I wish I could just subscribe to the Passinginterest channel so I don't miss a thing

"Half the world is looking for Jesus, and the other half is looking for more bass..."
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Old 02-24-2012, 09:05 AM - Thread Starter
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MJAudio--You're such a funny guy! Thanks.

Quote:
Originally Posted by BeerParty View Post

I think you should have used more clamps just to make redzone jealous.

Haha! Very funny! I would never do such a thing. Or would I?

Quote:
Originally Posted by BeerParty View Post

...and that's why I have not started building my curved cabinet yet. I am waiting for you to show me the easy way to do it!

Well, I really only meant that you can glue and stack the side panels, then apply glue to the frame, position the panel-stack and clamping forms and begin clamping. So, it was quick and easy for that one operation.

But, you got me re-evaluating the process to make it easier overall, since not everyone will want to make the clamping forms like I used.
Still thinking.
I've had a few ideas this morning, but I'm looking for the easiest way before I begin.

"Still, a man hears what he wants to hear and disregards the rest." --Paul Simon The Boxer
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Old 02-25-2012, 07:31 AM - Thread Starter
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Well, I tried a different approach yesterday, but it was an epic fail.
I'll provide some pictures later.
I got the clamps closed nearly perfectly, before something let go and sent the clamps airborne.
Luckily, I stopped one 24" black-pipe clamp with my head, before it could damage anything important.

Pictures will follow later.

"Still, a man hears what he wants to hear and disregards the rest." --Paul Simon The Boxer
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Old 02-25-2012, 11:15 AM
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Quote:
Originally Posted by PassingInterest View Post

Well, I tried a different approach yesterday, but it was an epic fail.
I'll provide some pictures later.
I got the clamps closed nearly perfectly, before something let go and sent the clamps airborne.
Luckily, I stopped one 24" black-pipe clamp with my head, before it could damage anything important.

Pictures will follow later.

You ok? Lose consciousness?

JSS

JSS
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Old 02-25-2012, 12:54 PM
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Quote:
Originally Posted by PassingInterest View Post

Well, I tried a different approach yesterday, but it was an epic fail.
I'll provide some pictures later.
I got the clamps closed nearly perfectly, before something let go and sent the clamps airborne.
Luckily, I stopped one 24" black-pipe clamp with my head, before it could damage anything important.

Pictures will follow later.

Hope you didn't break the clamp, they're expensive.

Seriously - hope that you're alright. I've had things come apart like that while under pressure - it is always a surprise how much energy can be stored.
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Old 02-25-2012, 01:04 PM
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Usually when one lets go, a good portion if not all the others do as well. Hope you are A-OK, awaiting update.

 

Originally Posted by Bill Fitzmaurice:
It's also the very sort of Voodoo Engineering that should never be done.

 

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Old 02-25-2012, 01:06 PM - Thread Starter
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Thanks, guys.
I'm fine. It was just my head. I wasn't using it anyway.

WiSounds--You are so right. It was like a bow-and-arrow, the way the clamps were launched.

I've been doing yard work today, so no updates yet.

"Still, a man hears what he wants to hear and disregards the rest." --Paul Simon The Boxer
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Old 02-26-2012, 09:13 AM
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Quote:
Originally Posted by PassingInterest View Post

Thanks, guys.
I'm fine.

Glad to hear you are OK.

Chris

"It hurts to admit when you make mistakes - but when they are big enough, the pain only lasts a second."
--Despair, Inc. "Regret"

My AviaTrix TM Build
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Old 02-26-2012, 03:43 PM
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I am glad to hear your OK PI.

"Half the world is looking for Jesus, and the other half is looking for more bass..."
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Old 02-26-2012, 05:07 PM - Thread Starter
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Thanks, guys.

Here's Failed Attempt number 1.
I cut a pair of beveled cauls for the front and a pair for the rear, using the same bevel that was used on the front and rear panels (see the Howitzer thread).



Check.








Leave room for four 1/4" MDF panels on each side, but make it really tight.




Not secured well enough, it turns out.




Dry fit check with a single panel. I temporarily raised the frame to make it easier to squeeze in all the panels--it's a really tight fit.
During the real glue-up attempt, the piece of 2x stock was removed and the frame was clamped down hard, so it wouldn't move.




This was the last photo I took of this setup. The dry fit seemed okay, so I glued all 8 MDF panels and the frame and began applying the clamping pressure. I intended to take another shot after it was all clamped up, but the clamps got launched when the pieces at the top let go. It was nearly clamped perfectly when it failed. Just a little more pressure was needed.



This trick might have worked if I had made the panel a little longer, so I could put a C-clamp on each end without them interfering with the glue-up.

"Still, a man hears what he wants to hear and disregards the rest." --Paul Simon The Boxer
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Old 02-26-2012, 05:12 PM - Thread Starter
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Failed Attempt number 2--The Straps.




The caul slipped a little and even though the MDF was damaged at the edge, I got a tight fit to the front and back corners.






BUT, I had a gap in the middle on both sides. So this was a fail.



The newly arrived Curvomatic would have worked with the straps if it were the larger size. The one I have is 23 1/2" long and the cabinet is 28" tall.

Unfortunately, I can't spare more time for further experimentation right now, so I went back to the clamping forms. This summer I might experiment some more.


"Still, a man hears what he wants to hear and disregards the rest." --Paul Simon The Boxer
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Old 02-26-2012, 08:09 PM
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And so I stand corrected even with all those clamps... you COULD use a few more clamps! lol

still jealous though lol.
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Old 02-26-2012, 08:48 PM
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In order to bond the curved sides of the enclosure as you've seen you really need to use some sort of jig to hold the entire side onto the internal braces. I made these simple jigs when I made up my Ewave speakers a few years back. Very easy to make but very effective. The braces on the jig align with the top, bottom, and internal bracing to ensure that the pressure is applied where it is needed.

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Old 03-01-2012, 07:04 PM - Thread Starter
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tsloms--Very nice. Very practical. I think I over-complicated mine.

"Still, a man hears what he wants to hear and disregards the rest." --Paul Simon The Boxer
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