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Old 08-10-2014, 08:44 AM - Thread Starter
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Get Bent With A Curvy Volt-10

Volt-10 Curve Ball:

Calcumalations:










I use Durham's Rock hard putty to fill any gaps.



Woofer Cutouts Done





Did the sanding on the curves. Here is a comparo, the final result is pretty smooth:



Extreme Closeup!(Wayne's World Ref):


Sides on:



Now we are starting to look like a surround speaker:





Veneer:

Reconstituted Mascar Ebony



Contact cement used:



Also, the back panel requires some bracing. It resonates at about the same frequency as a tom drum on a drum kit so, bracing added:


Terminal cups in:



Veneer Time!



This is a "Carpet Chisel?" It works much better than a J roller in applying the needed pressure to get the contact adhesive activated:


Im really liking the look.




Now the tricky part:





Seams turned out nice n tight:



This is obviously without any finish:


Last edited by NicksHitachi; 09-10-2014 at 10:00 AM.
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Old 08-10-2014, 09:02 AM
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I like!
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Old 08-10-2014, 09:10 AM
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Sweet
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Old 08-10-2014, 09:43 AM
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Old 08-10-2014, 12:51 PM
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This is going to be cool!
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Dude, are you made of leprechauns? Cause that was awesome!

The Plains Theater Has Begun
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Old 08-10-2014, 01:03 PM - Thread Starter
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Thanks guys.

I really wanted to rear mount the woofer to improve aesthetics but i dont see a way to make that work with my bracing scheme.

Also, and i know this will draw criticism, but im gonna duratex em. Sorry, i know thats boring and plain but my theater is really simple and any extravagant finishing would just stand out.

Im at a point where i could prob finish them in a half day of work but i had to stop to let glue dry and pay the GF some attention, she gets pouty if i spend ALL day tinkering on my "nerd stuff"
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Old 08-10-2014, 01:25 PM
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Quote:
Originally Posted by Nick****achi View Post
Thanks guys.

I really wanted to rear mount the woofer to improve aesthetics but i dont see a way to make that work with my bracing scheme.

Also, and i know this will draw criticism, but im gonna duratex em. Sorry, i know thats boring and plain but my theater is really simple and any extravagant finishing would just stand out.

Im at a point where i could prob finish them in a half day of work but i had to stop to let glue dry and pay the GF some attention, she gets pouty if i spend ALL day tinkering on my "nerd stuff"
So, uh, does surfing AVS count as paying the GF attention? I need to figure out how you pulled that one off!
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Dude, are you made of leprechauns? Cause that was awesome!

The Plains Theater Has Begun
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Old 08-10-2014, 01:30 PM
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nice, how are you going to finish it?
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Old 08-10-2014, 01:45 PM - Thread Starter
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Quote:
Originally Posted by J_P_A View Post
So, uh, does surfing AVS count as paying the GF attention? I need to figure out how you pulled that one off!
Haha im multitasking

Quote:
Originally Posted by notnyt View Post
nice, how are you going to finish it?
Noobatex
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Old 08-11-2014, 06:28 AM
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how did you do the kerfs? the curve looks really good
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Old 08-11-2014, 06:57 AM - Thread Starter
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I used this kerfing 101 post from Mark at Caraudiofabrication.


You have to change some of the trigonometry to accomodate different angles other than 90 degree bends but its not that difficult. There was some trial and error too, I screwed up three pieces and had to start over. The first didn't have enough angle for my listening positions so I had to scrap that prototype. The second I didn't have the saw set deep enough and the MDF didn't want to bend. The third, I just plain screwed up and ruined it.

So two out of five turned out good.

Calcumalations:

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Old 08-11-2014, 10:00 AM
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If your not making mistakes the projects too easy [emoji48]
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Old 08-11-2014, 03:21 PM
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Quote:
Originally Posted by chalugadp View Post
If your not making mistakes the projects too easy [emoji48]
+1 Right on.

Nice build Nick.
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Old 08-11-2014, 05:21 PM - Thread Starter
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Quote:
Originally Posted by chalugadp View Post
If your not making mistakes the projects too easy [emoji48]
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Originally Posted by tuxedocivic View Post
+1 Right on.

Nice build Nick.

Thanks.

Woofer Cutouts Done



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Last edited by NicksHitachi; 08-29-2014 at 04:45 AM.
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Old 08-28-2014, 05:44 AM - Thread Starter
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I've been traveling the last few weekends. West Jefferson NC weekend before last and Myrtle Beach last weekend.

Oh, and school started today for my 12yr old son too... Man time flies.

However, this weekend I'm home and weather looks good so should get these closed up, maybe even ready for finish by the end of the weekend....

Minor design change, I'm gonna reduce their depth by 4" to get the power handling up and excursion down at my intended crossover of 80Hz. I'm gonna shoot for an interior volume of 0.5-0.6ft^3 which seems to keep excursion under control when AVR bass management is taken into consideration.
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Old 08-28-2014, 09:00 AM
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Are those rounded edges smooth or are they a bit rippled. It's hard to tell whether it's an illusion or not.
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Old 08-28-2014, 09:11 AM
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With the kerfs allowing the bending, the outside radius doesn't come out perfectly smooth since the MDF basically bends where it's thin. You can kind of see that in the second photo in the thread. It should sand smooth without too much trouble.
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Old 08-28-2014, 09:23 AM - Thread Starter
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Quote:
Originally Posted by JohnDean View Post
Are those rounded edges smooth or are they a bit rippled. It's hard to tell whether it's an illusion or not.
There are high spots at the kerf bend points before sanding.

You gotta run the palm sander over the ridges a few times to knock them down. After that some all over sanding attention on the curve and it comes out smooth.
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Old 08-28-2014, 09:25 AM
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Quote:
Originally Posted by rhodesj View Post
With the kerfs allowing the bending, the outside radius doesn't come out perfectly smooth since the MDF basically bends where it's thin. You can kind of see that in the second photo in the thread. It should sand smooth without too much trouble.
That's what I figured but wasn't sure if it was even noticable or necessary after light sanding/paint.
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Old 08-28-2014, 09:31 AM - Thread Starter
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It depends on your tolerance for the lines really. I can imagine some people wouldnt mind it but considering the work invested to get the kerfs to work, a little sanding don't bother me.....
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Old 08-28-2014, 11:33 AM
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10-4

I'm planning to try my hand at curves like this when I find a suitable application.
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Old 08-28-2014, 04:24 PM - Thread Starter
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Actually got a hot minute to myself!

Did the sanding on the curves. Here is a comparo, the final result is pretty smooth:



Extreme Closeup!(Wayne's World Ref):


Thought id share a little trick i learned a while ago. When gluing and clamping panels they often want to shift and move around since the glue acts like lubrication or bearings.

My solution:

Place panel dry in proper spot.

Drill small hole through both panel and mounting surface. Hole should be small enough to hold nail with friction.

Drive nail into panel.

Drill hole in mounting surface one size larger than nail so nail easily fits into hole.

Apply glue and use nails as guide pins.

Clamp her down! With the nails in place it wont shift during clamping.

After glue fully sets, pull the nails.



I got curves sanded and two sides glued on....
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Old 08-28-2014, 06:59 PM
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You could leave the cabs as is and add some filler to reduce volume. Blocks of cedar or balsa wouldn't weight much but would reduce volume and you could add or subtract to fine tune.
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Old 08-28-2014, 07:03 PM
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Nice work!

I'm glad I found this, I'm working on a rounded box right now using kerfing and wasn't sure what to use for filling in the kerf grooves so I started looking on here. I'll grab some hard putty tomorrow @ HD. Thanks for the tip!

Planning on a build thread here when I get time.
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Old 08-29-2014, 03:09 AM - Thread Starter
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^Hard putty works great for filling any resulting voids after gluing. Its a power so you gotta mix it up. You can make it as thin or thick as you want and it never goes bad since its powder.

Duratex will stick to it but application adhesion is lower than MDF so youll need a couple coats where the putty is largely exposed.

I used titebond II this time on the glue joints but PL Premeium works much better. I recommend the PL as it expands as it cures and fills the kerfs better and Durhams to fill anything else.
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Old 08-29-2014, 05:20 AM
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Thanks again Nicks.

I used PL premium on a horn sub project and it worked great, some messy stuff though. I was planning on picking some up today for this project also for putting things together.

I'll be veneering at some point and the kerfs are inside so I shouldn't have to worry about paint sticking.

At first I messed up and bought PL Wood instead of premium when doing my last project. I wish it expanded as it is some nice stuff to work with.

What do you run for mains (LCR)? The volts should be some potent surrounds.

Last edited by Jim Himes; 08-29-2014 at 05:24 AM.
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Old 08-29-2014, 05:25 AM - Thread Starter
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I always use nitrile gloves when using the stuff, your right its some messy stuff but for sealed cabs, its the only way to fly imo.

I use some DIY sealed mains with Eminence Delta 12LFA woofs under a SEOS 12 with DNA-360 CD.

I've been on a curved kick lately.
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Old 08-29-2014, 06:44 AM - Thread Starter
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Quote:
Originally Posted by Nick****achi View Post

Also, and i know this will draw criticism, but im gonna duratex em. Sorry, i know thats boring and plain but my theater is really simple and any extravagant finishing would just stand out.
Whelp, I have an update. I submitted an offer for some veneer from a supplier and didn't expect to win it but I did....

So these will be receiving veneer.
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Old 08-29-2014, 03:57 PM
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I like the look of your mains. They turned out very nice.

What kind of veneer are you using and where did you get it from?

Will stay tuned to see how the veneer turns out. Good luck!
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Old 08-29-2014, 07:31 PM
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Thumbs up

I can't wait to see these. Really nice craftsmanship!
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