For just a quick background on how I got to this point, over the course of 2011-2012, I bought a complete Polk Audio monitor series setup in addition to a (new at the time) Onkyo TX-NR808 receiver; all through Newegg, all on sale. This setup was replacing the 15 year old super cheapo Yamaha bookshelf speakers, cheapo JBL center channel and no surrounds situation that I had found myself in. With the Polks, I ended up with Monitor 70's for fronts, a CS2 center channel, Monitor 30's for surrounds and a PSW505 12" sub all in cherry except for the sub. And I was very happy with this setup for about 2 years. They looked nice, sounded ok and were a huge step-up from where I had been. I eventually got to thinking about adding a second PSW505 and then I started hanging out in the DIY forums here at AVS and over at HTS . As the story goes, it was all over from there. As word of the Stereo Integrity HT18" grew, and I kept up with all the development updates, I was finally ready to take the plunge and put my name on 2 of them during the first pre-order in the November/December time frame of 2012. You can see the results of that here: http://www.hometheatershack.com/forums/sealed-subwoofer-build-projects/67838-stereo-integrity-18-d2-curved-build.html
Just for the record, I have two more of them waiting in their shipping boxes for me to build into rear subs.....but that's a different thread for a different time.
I've followed the development of the Tux-1099 from the beginning and knew that this was the SEOS design that I had been waiting for. Watching Fatshaft's build progress and then reading all about the final impressions, I couldn't wait for my turn! Finally, after selling my entire Polk system (5 speakers plus the sub) in March, I was able to order up my first pair.
My plan is to make a pair of Tux towers with an overall height of ~54" which will put the waveguides at ear level for me in my room. For now, the only progress toward the cabinet builds are a couple of sketches on paper.
What I have made some headway on though are the crossovers. I haven't built any crossovers since high school, so please be kind!
The layouts, which I think look great:
The bottom sides are no showroom beauty queens, but they are solid, functional and correct. I will be hot gluing all the jumpers down tonight which will also help the appearance a bit.
I am grateful for Tux, Erich and the many, many others that make this community possible!
My priority is getting the center channel completed because that is by far the worst part of my temporary setup. Once the 1099 center channel is done, my temporary setup will consist of Volt-10's (in slanted surround boxes) as front L + R, and 2 SI 18"s sealed plus the 1099 center (obviously). I think that should hold me over until I can get a start on the 1099 fronts. Anyway......moving onward!
Find a radius for the curved top of the center channel:
I like the shape of that one but after making some cuts, I decided I wanted the template made out of MDF instead of that plywood. I used the cutoff section of plywood and ran the base of my router up against that while the bit was on top of a piece of MDF. I then cut that board to its final measurements and made three copies of it using the router table and a flush trim bit.
Last edited by dtsdig; 07-17-2014 at 08:57 AM.
Here's my table setup which uses sacrificial 2x4's to cut on.
And now for some fun!
Last edited by dtsdig; 07-17-2014 at 09:07 AM.
Knowing that I would need a nice, tight seam where the front edges of the curved layers meet the back top edge of the baffle, I decided to only glue up the box's sides, back and divider panels so that I could bend the wood over the whole top and then trim it later to mate up to the baffle.
I installed some temporary braces where the baffle will eventually be just to keep everything square and solid.
And away we go! What a freakin pain!
To finish up yesterday, I added some small plywood blocks to the back of the baffle only for the woofer screws to bite into. The baffle is thick enough for the waveguide and the mids to grab into just fine but I wanted some extra reinforcement for those heavy woofers.
Tonight, I'll pull the clamps off and see how it all holds up. The top will be 3 layers thick resulting in about a 3/4" total thickness. :)
Last edited by dtsdig; 07-17-2014 at 09:08 AM.
Looking forward to your hearing impressions
The "ugly" looks a hell of a lot cleaner then mine haha. Looking forward to the build!
I should be finishing up my cabs and painting this weekend. Hopefully some listening Monday or Tuesday!
I'm glad i'm not the only one who's running behind. At least your further ahead of me with your crossovers already built! I too am dragging my feet. I would have had my Alchemy8's done on Wednesday, but after painting them outside and leaving them outside, some bugs decided that wet paint was a beautiful place to die. Ergo, some more sanding and painting.
Sadly, that is the only update I have for this thread. Now back to work on the other zillion house projects that are in the way of me starting any speaker builds.
To cut the curves, the first pic shows how to set up a long swing arm with the router attached to it so you can create whatever kind of radius you want. I knew what I needed the front height and the rear height at the back of the box to be so I just experimented with the swing arm a bit to match up to the start and end points (heights).
These boxes will not have any round overs because they will eventually be veneered and I'll need sharp corners for that.
BTW, you build beautiful cabs!
Last edited by dtsdig; 07-17-2014 at 09:10 AM.
Now comes that time in the build where I have to recognize the mistake(s), and move forward. The first issue that I realized about half way through dinner last night is that because I didn't put any kind of support across the top front edge of the box internals, I had nothing for the curved layers to bond to between the braces and side pieces. I ended up with this wavy effect:
Secondly, I realized that once I go and join the back, sides, braces, curved top portion to the bottom and baffle assembly, the spans between that I mentioned above would have no way to bond with the baffle. Duh. Time to undo what I have done and get this back on the right path:
Tonight I am going to purchase actual Italian Bending ply from a local shop which is what I should have done in the first place. As far as I know, this will allow me to make the curved layers without each of them having to be under extreme pressure and just waiting to pop themselves apart.
First I have to clean up all this PL Premium and add the braces I mentioned above. More to come!
Last edited by dtsdig; 07-17-2014 at 09:14 AM.