Stentorian x3 & Sten II x4 Theater Build - AVS Forum
Forum Jump: 
Reply
 
Thread Tools
post #1 of 54 Old 06-08-2013, 03:22 PM - Thread Starter
AVS Special Member
 
Mr.Tim's Avatar
 
Join Date: Jul 2004
Location: SC
Posts: 2,054
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 4 Post(s)
Liked: 51
So I'm finally getting around to building my Stens/Sten II's to be used in my home theater. For the Stentorians I will be going with the standard tower build (not PA). They'll be upside down, which will put the tweeter just about exactly at ear level.

The carcasses of the Stentorians and Sten IIs is 3/4" "cabinet grade" plywood from Home Depot (IIRC the skew is 175-171). I've used about a dozen sheets of it on various things and it is pretty decent. I haven''t noticed any voids. It's pine instead of birch.

The baffles on both will be MDF so I can get a nice profile on the edge. The Stentorians will have a double baffle. I made the carcasses of the Stentorians 3/4" deeper so I can recess one baffle inside.

Tim
Mr.Tim is offline  
Sponsored Links
Advertisement
 
post #2 of 54 Old 06-08-2013, 03:25 PM - Thread Starter
AVS Special Member
 
Mr.Tim's Avatar
 
Join Date: Jul 2004
Location: SC
Posts: 2,054
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 4 Post(s)
Liked: 51
Here's some Stentorian stuff:

IMG_1705.JPG

There are 3/8" deep x 3/4" wide rabbets to accept the rear panel and one of the two front baffles. The top and bottom have 3/8" rabbets.

Tim
Mr.Tim is offline  
post #3 of 54 Old 06-08-2013, 03:33 PM - Thread Starter
AVS Special Member
 
Mr.Tim's Avatar
 
Join Date: Jul 2004
Location: SC
Posts: 2,054
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 4 Post(s)
Liked: 51
I've progressed a lot further on the Sten II's, here's the pieces I started with:

IMG_1700.JPG



Like the Stenorians, the Sten II's have a 3/4" rabbet on the backs so the rear panel will be recessed into the cabinet. The rear panel has no rabbets, it's just ripped on the table saw to fit:

IMG_1704.JPG



Likewise, the tops and sides have 3/8" rabbets and interlock:

IMG_1702.JPG



Here's the assembly with the bracing. I would probably make the braces on the sides a bit wider if I were to do it again:

IMG_1707.JPG



The front of the carcass has a 1/4" rabbet. This will accept the front MDF baffle. 1/4" will be recessed in the carcass and 1/2" of the MDF will stand proud:

IMG_1703.JPG


I was really pleased with the fit:

IMG_1708.JPG
Mr.Tim is offline  
post #4 of 54 Old 06-08-2013, 07:52 PM
Advanced Member
 
filtor1's Avatar
 
Join Date: Feb 2008
Location: Florida
Posts: 929
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 4 Post(s)
Liked: 22
Very nice!
filtor1 is offline  
post #5 of 54 Old 06-09-2013, 11:39 AM - Thread Starter
AVS Special Member
 
Mr.Tim's Avatar
 
Join Date: Jul 2004
Location: SC
Posts: 2,054
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 4 Post(s)
Liked: 51
Quote:
Originally Posted by filtor1 View Post

Very nice!

Thank you! I have the four Sten II's ready for paint and lacquer:

DSC_0033.JPG



Currently gluing up the Stentorians.. What a pain-- those suckers are big! Need more clamps!!

Tim
Mr.Tim is offline  
post #6 of 54 Old 06-09-2013, 05:12 PM - Thread Starter
AVS Special Member
 
Mr.Tim's Avatar
 
Join Date: Jul 2004
Location: SC
Posts: 2,054
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 4 Post(s)
Liked: 51
Got two of the three carcasses for the Stentorians glued up:

DSC_0038.JPG


I put a 1/8" dado in the sides to accept the dividers between the woofer compartments. I didn't dado the front or the back.. If the dados in the sides are off a little from each other this way is more forgiving.

Tim
Mr.Tim is offline  
post #7 of 54 Old 06-09-2013, 06:25 PM
AVS Special Member
 
J_P_A's Avatar
 
Join Date: Dec 2008
Location: L.A. - Lower Alabama
Posts: 4,119
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 245 Post(s)
Liked: 254
Nice! You guys are making it tough not to start a speaker build smile.gif

Dude, are you made of leprechauns? Cause that was awesome!

The Plains Theater Has Begun
J_P_A is offline  
post #8 of 54 Old 06-09-2013, 07:03 PM
AVS Special Member
 
HopefulFred's Avatar
 
Join Date: Mar 2007
Location: Atlanta, GA
Posts: 2,760
Mentioned: 1 Post(s)
Tagged: 0 Thread(s)
Quoted: 135 Post(s)
Liked: 194
Quote:
Originally Posted by J_P_A View Post

Nice! You guys are making it tough not to start a speaker build smile.gif
Maniacal Laugh! Maniacal Laugh!

What kinds of finishing treatments are you planning Tim? Your work looks very good, but I have more confidence in my ability to get a nice finish on MDF versus the ply.
HopefulFred is offline  
post #9 of 54 Old 06-10-2013, 04:17 PM - Thread Starter
AVS Special Member
 
Mr.Tim's Avatar
 
Join Date: Jul 2004
Location: SC
Posts: 2,054
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 4 Post(s)
Liked: 51
Quote:
Originally Posted by J_P_A View Post

Nice! You guys are making it tough not to start a speaker build smile.gif

Come along for the ride! Hop in the van, we have free candy biggrin.gif

Quote:
Originally Posted by HopefulFred View Post

Maniacal Laugh! Maniacal Laugh!

What kinds of finishing treatments are you planning Tim? Your work looks very good, but I have more confidence in my ability to get a nice finish on MDF versus the ply.

I got a nice satin finish on my sub.. but I am going for more of a piano black on these. To wit, I got some of this:



Which I think should smooth out the plywood nicely. I've never used it before, so it's quite experimental.

I'm following up with my favorite base coat of all time:



It's a high solids primer that sands exceptionally smooth.

And lastly, another inaugural event with this:



I'll be using the gloss lacquer, not satin. I'm going to wet sand and polish, which should get me a nice finish.

With the exception of the two rear surrounds, all the speakers will be hidden so this is really just another experiment.

TIm
Mr.Tim is offline  
post #10 of 54 Old 06-16-2013, 05:29 PM - Thread Starter
AVS Special Member
 
Mr.Tim's Avatar
 
Join Date: Jul 2004
Location: SC
Posts: 2,054
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 4 Post(s)
Liked: 51
Ready for paint in this pic:

DSC_0048.JPG



I used the dimensions from the Sten build for the tweeter cutout. It is *tight*. When I do the Stens I am going to add 1/16. Due to how tight they are I cut some round plugs to fit in the holes. The plugs will keep any paint from building up in the opening.

Since that pic I sprayed two coat of black, blocked it flat and put two more coats on.

Hopefully I'll block it flat again and get a few coats of lacquer on them tomorrow.
Mr.Tim is offline  
post #11 of 54 Old 06-16-2013, 05:41 PM
AVS Special Member
 
HopefulFred's Avatar
 
Join Date: Mar 2007
Location: Atlanta, GA
Posts: 2,760
Mentioned: 1 Post(s)
Tagged: 0 Thread(s)
Quoted: 135 Post(s)
Liked: 194
Are you using one of the Graco HVLP sprayers? And do you have any comments on thinning the general undercoat?
HopefulFred is offline  
post #12 of 54 Old 06-16-2013, 05:55 PM - Thread Starter
AVS Special Member
 
Mr.Tim's Avatar
 
Join Date: Jul 2004
Location: SC
Posts: 2,054
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 4 Post(s)
Liked: 51
Quote:
Originally Posted by HopefulFred View Post

Are you using one of the Graco HVLP sprayers? And do you have any comments on thinning the general undercoat?

Yes, I'm using the "noname" Graco sprayer that Mississippi Mud Man recommends. I bought the smaller needle for it to spray the waterbased finishes (1.5mm IIRC). I have sprayed without thinning, but for better results I've been adding 2 medicine cups of water (50 ml) per 16oz and it's been working nicely.

Tim
Mr.Tim is offline  
post #13 of 54 Old 06-18-2013, 01:03 PM
AVS Addicted Member
 
Mfusick's Avatar
 
Join Date: Aug 2002
Location: Western MA
Posts: 22,408
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 146 Post(s)
Liked: 776
I am curious to hear what you think about them and how they sound. Looking good!

-

"Too much is almost enough. Anything in life worth doing is worth overdoing. Moderation is for cowards."
Mfusick is offline  
post #14 of 54 Old 06-19-2013, 05:29 PM - Thread Starter
AVS Special Member
 
Mr.Tim's Avatar
 
Join Date: Jul 2004
Location: SC
Posts: 2,054
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 4 Post(s)
Liked: 51
Quote:
Originally Posted by Mfusick View Post

I am curious to hear what you think about them and how they sound. Looking good!

Soon enough, my friend. Soon enough. Unfortunately the drivers are now scarce, so building a set will be difficult if not costly.

Here's the Sten Ii's after 3 coats of high build primer:

DSC_0061.JPG

And after I blocked them flat:

DSC_0062.JPG


At this point I have 3 coats of lacquer on them. I haven't worked with lacquer in a long time, and even when I did it was on some windows.. not exactly something that needed to be perfect. Let me tell you, lacquer is not forgiving. After the first coat it looked pretty crappy-- you could see the gray and black areas just like you see them after I blocked them. The second coat got rid of some of it, but still pretty visible. It seems that the third coat has just about blended everything to a nice uniform black.

However, you can see every little area where I screwed up on prep. Little high points where I didn't sand the plywood enough, little spec of putty etc. Not the end of the world, but it does deem to reinforce the fact that most of a finish is prep work.

I think I will block them flat again, then tint the lacquer a bit with some black primer for three more coats.

Tim
Mr.Tim is offline  
post #15 of 54 Old 06-19-2013, 06:26 PM
AVS Addicted Member
 
Mfusick's Avatar
 
Join Date: Aug 2002
Location: Western MA
Posts: 22,408
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 146 Post(s)
Liked: 776
coat. Sand. Coat. Sand. coat. Sand. Finish. Sand. Finish. Sand. Finish. Finish.

Once you think you did enough.. go back and finish it one more time just for overkill.

Excess wins when trying for perfection.

Personally.. I am just going to flat black mine and stick them behind the screen. I don't think I will care much what they look like. I will hide them all in the room in false walls and false columns.

I have been watching theater builds like yours and DIY speaker projects trying to follow along. I have appointment with Bank on saturday. Hopefully starting construction this summer and theater soon after. I am confused and noob about DIY speakers so I am trying to figure out how I want to go.

What is your planned project total cost ?? (for the speakers)

-

"Too much is almost enough. Anything in life worth doing is worth overdoing. Moderation is for cowards."
Mfusick is offline  
post #16 of 54 Old 06-23-2013, 08:11 AM - Thread Starter
AVS Special Member
 
Mr.Tim's Avatar
 
Join Date: Jul 2004
Location: SC
Posts: 2,054
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 4 Post(s)
Liked: 51
Lots of windowpane braces... Glad I set up a jig and used the router+spiral bit.

IMG_1712.JPG


Reallllllly not looking forward to cutting all of those driver holes.

Tim
Mr.Tim is offline  
post #17 of 54 Old 06-23-2013, 01:15 PM - Thread Starter
AVS Special Member
 
Mr.Tim's Avatar
 
Join Date: Jul 2004
Location: SC
Posts: 2,054
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 4 Post(s)
Liked: 51
I wasn't sure if my little PC router was gonna make it. By the time I was done it was smokin hot:

IMG_1713.JPG


That was an adventure..

Tim
Mr.Tim is offline  
post #18 of 54 Old 06-23-2013, 01:30 PM
AVS Addicted Member
 
Mfusick's Avatar
 
Join Date: Aug 2002
Location: Western MA
Posts: 22,408
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 146 Post(s)
Liked: 776
Wow! Looks great! I guess you've been working hard smile.gif

-

"Too much is almost enough. Anything in life worth doing is worth overdoing. Moderation is for cowards."
Mfusick is offline  
post #19 of 54 Old 06-23-2013, 02:14 PM
AVS Special Member
 
Mrkazador's Avatar
 
Join Date: Jun 2005
Posts: 3,844
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 44 Post(s)
Liked: 250
Quote:
Originally Posted by Mr.Tim View Post

I wasn't sure if my little PC router was gonna make it. By the time I was done it was smokin hot:

IMG_1713.JPG


That was an adventure..

Tim

 

How long did it take you to cut out all those holes? I probably would have went crazy after the 10th hole.

Mrkazador is online now  
post #20 of 54 Old 06-23-2013, 02:33 PM
AVS Addicted Member
 
Mfusick's Avatar
 
Join Date: Aug 2002
Location: Western MA
Posts: 22,408
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 146 Post(s)
Liked: 776
so how many of these are you building? Your making a full 7.2 set (7 of them?)

I'd love to see more pictures as you work your way through the build.

-

"Too much is almost enough. Anything in life worth doing is worth overdoing. Moderation is for cowards."
Mfusick is offline  
post #21 of 54 Old 06-23-2013, 03:02 PM
AVS Special Member
 
HopefulFred's Avatar
 
Join Date: Mar 2007
Location: Atlanta, GA
Posts: 2,760
Mentioned: 1 Post(s)
Tagged: 0 Thread(s)
Quoted: 135 Post(s)
Liked: 194
Those are the double baffles of three Stentorians. The four Sten II's round out the set.
HopefulFred is offline  
post #22 of 54 Old 06-23-2013, 05:24 PM - Thread Starter
AVS Special Member
 
Mr.Tim's Avatar
 
Join Date: Jul 2004
Location: SC
Posts: 2,054
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 4 Post(s)
Liked: 51
Quote:
Originally Posted by Mrkazador View Post

How long did it take you to cut out all those holes? I probably would have went crazy after the 10th hole.

I cut the inner baffles yesterday and the outer baffles today. I'd say it was probably an hour or so for the inner and 2 for the outer. The one saving grace was that I made a template for the cutouts before I started. I drilled 1/8" holes through the 1/4" template at the center of each speaker opening. That made the layout go quickly.

The other thing I did was put a 1/2" mortising bit in for the driver recess. I was able to cut the recess in one pass. Then I switched to the 1/4" spiral and cut the hole all the way through with a second pass. That was also a great time saver.

But yes, I thought it would never end.

Quote:
Originally Posted by Mfusick View Post

so how many of these are you building? Your making a full 7.2 set (7 of them?)

I'd love to see more pictures as you work your way through the build.

# Stens for LCR.. thank goodness I didn't decide to do 7 of them. If I had to do 7 I would add the cost of a CNC machine to my projected cost!

Quote:
Originally Posted by HopefulFred View Post

Those are the double baffles of three Stentorians. The four Sten II's round out the set.

Yes, and the Sten II's have 9 coats of gloss black lacquer on them biggrin.gif I just got back from HD, which apparently doesn't have any sandpaper finer than 800 grit. Need to pick up some 1000 and 1500 prior to buffing them out.

Tim
Mr.Tim is offline  
post #23 of 54 Old 06-23-2013, 07:04 PM
AVS Special Member
 
J_P_A's Avatar
 
Join Date: Dec 2008
Location: L.A. - Lower Alabama
Posts: 4,119
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 245 Post(s)
Liked: 254
Quote:
Originally Posted by Mr.Tim View Post

.........
# Stens for LCR.. thank goodness I didn't decide to do 7 of them. If I had to do 7 I would add the cost of a CNC machine to my projected cost!......

That sounds like a good reason to go with 7 of them to me smile.gif You're making great progress! Between this speaker build and your theater, you might be the most productive guy on the forum smile.gif

Dude, are you made of leprechauns? Cause that was awesome!

The Plains Theater Has Begun
J_P_A is offline  
post #24 of 54 Old 06-23-2013, 07:13 PM
AVS Special Member
 
HopefulFred's Avatar
 
Join Date: Mar 2007
Location: Atlanta, GA
Posts: 2,760
Mentioned: 1 Post(s)
Tagged: 0 Thread(s)
Quoted: 135 Post(s)
Liked: 194
Quote:
Originally Posted by Mr.Tim View Post

I just got back from HD, which apparently doesn't have any sandpaper finer than 800 grit. Need to pick up some 1000 and 1500 prior to buffing them out.
You might look at NAPA. At work we use the 3M headlight refinishing kit that uses 3M's 1000 and 3000 grit wet-sanding pads. NAPA sells them to us. Do you have a polisher or random orbit sander that can work with 3-inch hook and loop (velcro) discs? Here's the products, and NAPA probably has the parts, but you'll need to bring the part numbers with you. They're not cheap, but nice. http://3mcollision.com/products/headlight-lens-restoration/3m-headlight-lens-restoration-kit-02516.html If you have a power tool (or the diligence to do it by hand) you'll want the hookit discs and the soft interface pad (for the power tool).
HopefulFred is offline  
post #25 of 54 Old 06-24-2013, 03:16 AM - Thread Starter
AVS Special Member
 
Mr.Tim's Avatar
 
Join Date: Jul 2004
Location: SC
Posts: 2,054
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 4 Post(s)
Liked: 51
Quote:
Originally Posted by J_P_A View Post

That sounds like a good reason to go with 7 of them to me smile.gif You're making great progress! Between this speaker build and your theater, you might be the most productive guy on the forum smile.gif

I'm not so sure about that, but this weekend was fairly productive smile.gif

Quote:
Originally Posted by HopefulFred View Post

You might look at NAPA. At work we use the 3M headlight refinishing kit that uses 3M's 1000 and 3000 grit wet-sanding pads. NAPA sells them to us. Do you have a polisher or random orbit sander that can work with 3-inch hook and loop (velcro) discs? Here's the products, and NAPA probably has the parts, but you'll need to bring the part numbers with you. They're not cheap, but nice. http://3mcollision.com/products/headlight-lens-restoration/3m-headlight-lens-restoration-kit-02516.html If you have a power tool (or the diligence to do it by hand) you'll want the hookit discs and the soft interface pad (for the power tool).

I have the pads (5-1/2") for my random orbit sander and I have 3M polishing compound. I need to pick up some fine compound and the paper. NAPA was on my short list. The 3" kit is pretty cool. I didn't even know they made pads that small.

I'll wait until next weekend to start that, which will give the lacquer a week to cure.

Tim
Mr.Tim is offline  
post #26 of 54 Old 06-24-2013, 05:36 AM
AVS Addicted Member
 
Mfusick's Avatar
 
Join Date: Aug 2002
Location: Western MA
Posts: 22,408
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 146 Post(s)
Liked: 776
I'm looking forward to more pics !

-

"Too much is almost enough. Anything in life worth doing is worth overdoing. Moderation is for cowards."
Mfusick is offline  
post #27 of 54 Old 06-27-2013, 03:44 AM - Thread Starter
AVS Special Member
 
Mr.Tim's Avatar
 
Join Date: Jul 2004
Location: SC
Posts: 2,054
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 4 Post(s)
Liked: 51
Quote:
Originally Posted by Mfusick View Post

I'm looking forward to more pics !

One more to keep the thread going:



That is after the compound, but before polishing. It was getting dark outside, so the image is kind of grainy. I still have to buff with the glazing compound and put some sort of finish on it.. maybe Zaino.

Steps I used:

1. Three coats of black underbody, using 320 grit paper between coats.
2. Three full coats of lacquer, blocked flat with 600 grit after 24hours
3. Repeat #2
4. Repeat #2
5. Wet sand with 600 grit
6. Wet sand with 1500 grit
7. Compound with random orbit sander

I used Turtle Wax rubbing compound applied with Sufbuf pad on my Porter Cable random orbit sander.

Mr.Tim is offline  
post #28 of 54 Old 06-27-2013, 12:04 PM
AVS Addicted Member
 
Mfusick's Avatar
 
Join Date: Aug 2002
Location: Western MA
Posts: 22,408
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 146 Post(s)
Liked: 776
I am envious. I want to do something like this for my theater build.

-

"Too much is almost enough. Anything in life worth doing is worth overdoing. Moderation is for cowards."
Mfusick is offline  
post #29 of 54 Old 06-28-2013, 04:51 PM
Member
 
scorpio516's Avatar
 
Join Date: Sep 2009
Posts: 25
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
Liked: 12
Looking forward to the finish! And listening impressions.

Your doing almost exactly what I'm planning, but I'm going to use different subs
scorpio516 is offline  
post #30 of 54 Old 06-28-2013, 05:15 PM - Thread Starter
AVS Special Member
 
Mr.Tim's Avatar
 
Join Date: Jul 2004
Location: SC
Posts: 2,054
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 4 Post(s)
Liked: 51
All the parts to finish have arrived. Lots of polyfil from walmart and a box of goodies from PE.

I just polished the Zaino off and they are looking pretty nice. I will snap some photos if it isn't raining tomorrow.

One thing I noticed was that I needed to spend more time with the 1500 grit paper. Unfortunately I only had 600 and 1500. I really need another step between.

The 1500 just didn't take some of the scratches from the 600 out. I guess that with enough muscle I could do it, but I think an intermediate step is the way to go.

Consequently I do have some scratches remaining that the compound just won't get out. I'm afraid I'll burn through if I try any more, especially on the baffle where the wood is narrow. This was just a trial run for the subs, so I'm thankful for the learning experience.

Tim
Mr.Tim is offline  
Reply DIY Speakers and Subs

User Tag List

Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page


Forum Jump: 

Posting Rules  
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off