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post #1 of 101 Old 04-20-2012, 07:08 PM - Thread Starter
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I finally got started building some plywood boxes for the things in these cardboard boxes. Muchas gracias to Erich.
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post #2 of 101 Old 04-20-2012, 07:10 PM
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/rubbing hands together excitedly

Can't wait for more pics!
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post #3 of 101 Old 04-20-2012, 07:51 PM - Thread Starter
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I started with the top, bottom and sides. Material is 3/4" AraucoPly.
One box on the floor, another on the bench, number three in clamps, four leaning on the doghouse waiting to be assembled.

 

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post #4 of 101 Old 04-20-2012, 07:52 PM - Thread Starter
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Can't have too many clamps.

 

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post #5 of 101 Old 04-20-2012, 07:53 PM - Thread Starter
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Another view. Helpers are hanging in the shadows.

 

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post #6 of 101 Old 04-20-2012, 07:56 PM - Thread Starter
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I cut dados in the top and bottom pieces and along the front and back of all four sides (to receive bracing). Dados make assembly so easy - no nails or screws, just Titebond II wood glue. Bessey K body clamps are a wonderful piece of engineering.

 

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post #7 of 101 Old 04-20-2012, 07:58 PM - Thread Starter
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Closeup of the dado

 

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post #8 of 101 Old 04-20-2012, 07:59 PM - Thread Starter
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Number four in the clamps.

 

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post #9 of 101 Old 04-20-2012, 08:13 PM - Thread Starter
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Bracing the corners. I nailed plywood triangles into the dados. I had to clamp one box corner-to-corner to square it up. All the others were within 1/16" on the diagonal measurements.

 

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post #10 of 101 Old 04-20-2012, 08:14 PM - Thread Starter
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Closeup of the corner braces. I'll eventually glue the front and back baffles to these braces.

 

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post #11 of 101 Old 04-20-2012, 08:15 PM - Thread Starter
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Another closeup. Dado is ready to receive the corner brace.

 

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post #12 of 101 Old 04-20-2012, 08:16 PM - Thread Starter
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Before I nailed the braces in I pulled them tight to the corner with a clamp. That forced the warped plywood flat and made the corners square.

The pocket holes don't have any function in these boxes. The braces were cut out of left over scraps from my oak coffered ceiling project.

 

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post #13 of 101 Old 04-20-2012, 08:19 PM - Thread Starter
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Big stack of braced boxes.

 

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Time for a Samual L. Jackson.


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post #14 of 101 Old 04-20-2012, 08:26 PM - Thread Starter
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I made a quick and dirty jig to nail up braces. I just used the finish nailer to attach wood scraps to the bench top.

 

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post #15 of 101 Old 04-20-2012, 08:27 PM - Thread Starter
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Here's a brace in the jig, freshly nailed.

 

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post #16 of 101 Old 04-20-2012, 08:28 PM - Thread Starter
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A few braces made and a stack of sticks in line for glue and nails.

 

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post #17 of 101 Old 04-20-2012, 08:28 PM - Thread Starter
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Finished braces ready to install in the boxes.

 

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post #18 of 101 Old 04-20-2012, 08:30 PM - Thread Starter
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Closeup of bracing. X marks the bottom.

 

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That's all I got done on day two. Must have been the Samuel L. Jacksons.


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post #19 of 101 Old 04-20-2012, 08:43 PM - Thread Starter
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Day Three...
More bracing. I installed four more sticks to brace the middle of the panels. I cut the ends at a 3 degree angle so I could tap the sticks into place without bowing the panels out. I didn't nail the ends but the braces are nailed together at the intersection. I've got gobs of glue everywhere.

 

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post #20 of 101 Old 04-20-2012, 08:44 PM - Thread Starter
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More bracing. I've added more sticks to connect the first set of braces to the cross braces. Are we done yet? I think so....

 

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post #21 of 101 Old 04-20-2012, 08:49 PM - Thread Starter
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Test fit. The driver is sitting on the brace in this shot. The back of the speaker will be about 1/4" from the brace once I have the baffle mounted.

 

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post #22 of 101 Old 04-20-2012, 08:52 PM - Thread Starter
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Next steps....
Rough sanding of the rabbit joints.
True up the edges where the front and rear baffles go. (mostly clean up glue squeeze out).
Do a round-over on the corners.
Fabricate baffles - I have a sheet of Chinese birch plywood for baffles.

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post #23 of 101 Old 04-21-2012, 03:34 AM
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very nice work Pete...
Are you going to stuff your cabs with polyfill?

My Build Thread
Equipment Speakers:
3x 1099's for LCR duty
4x Fusion 8's for surround duty
8x subs: 4x FTW21's and 4x SI18's
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post #24 of 101 Old 04-21-2012, 05:48 AM - Thread Starter
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Quote:
Originally Posted by Fatshaft View Post

...Are you going to stuff your cabs with polyfill?

What's the general consensus about stuffing? I've heard it makes the cabinet model slightly larger. Any other audible effects? This is my first speaker construction project so any suggestions are welcome.

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post #25 of 101 Old 04-21-2012, 07:45 AM
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Just a heads-up, if you haven't already, take those woofers out of the box. I noticed, with mine, when boxed up, the surrounds push up against the cardboard, which forces the cone in a little. After being boxed up for a while, I noticed my woofer cones, at rest, settled in (towards magnet) from center. If you can, have them in a down firing situation/position for a while so gravity will help push those cones back to rest in the center of their stroke.

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post #26 of 101 Old 04-21-2012, 08:17 AM - Thread Starter
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Thanks for the heads-up Looney. I'm off to the Big Orange Box for tee nuts and a new router bit...

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post #27 of 101 Old 04-21-2012, 08:51 AM
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All looking good. Seems like a LOT of bracing; at least you know those boxes won't be going anywhere!

Depending on how much power you're giving each, and how hard you're driving them, AIUI, stuffing a pillow or two in each will help with efficiency, but might make you reach xmax a little sooner (higher up in frequency).
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post #28 of 101 Old 04-21-2012, 10:16 AM - Thread Starter
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I'll be driving them with a BK 5000 series II five channel amp rated at 145 into four ohms.

I think I'll run them unstuffed to start. I'm not going to do any wood finishes right away - can always stuff later when I take the drivers out to finish the cabs.

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post #29 of 101 Old 04-21-2012, 10:20 AM - Thread Starter
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Quote:
Originally Posted by nube View Post

...Seems like a LOT of bracing....

OCD on display. I kept adding sticks until the "rap test" gave a consistent sound everywhere. I'll calculate internal volume now that the bracing is in place.

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post #30 of 101 Old 04-21-2012, 10:45 AM
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Nice work,I see your're well equipped.What are you gonna power them with?

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