Fusion-4 Tower Build - AVS | Home Theater Discussions And Reviews
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post #1 of 34 Unread 05-13-2015, 11:15 PM - Thread Starter
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Fusion-4 Tower Build

I told a friend of mine I'd build him a 7.2 setup. So far I've got everything done except the L/C/R (Alreay done is a pair of MicroMarty subs and Swope MTs for surrounds).

He wants the L/R speakers to be floor standing so I'm modifying the design a bit. Here is what they should look like when they are done:


I didn't bother adding driver cutouts to the SketchUp model, but you should get the idea.

I got all my goodies from Erich H today:


Now it time to start making some sawdust:


All my pieces are ready to go:


The gluing begins:
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post #2 of 34 Unread 05-14-2015, 11:13 AM
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being a nice guy in that regard, yeah, I can build that, great way to spend time


needless to say, for many, nearly almost, here, building is hands on validation of the capacity to know how to do stuff, the right stuff and the right way
confidence that carries thru


and we're competent enough to have fun with it too, very important


how about a follow up wrt the room, layout, equipment, subs etc. where this set up is going and


any possibilities of REW or other EQ / treatment etrc. work to follow up?
folks that have space issues could be very interested in the synergistic WOW factors


Just like to see a good plan come together

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post #3 of 34 Unread 05-14-2015, 11:49 AM
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Sub'd Thanks for the pics and can't wait to see more!
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post #4 of 34 Unread 05-14-2015, 09:48 PM - Thread Starter
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Since you asked here are some pics of the subs and surrounds:




The room will definitely be getting some REW treatment when the time comes. I'll be sure to post the results!

"Nothing prevents people from knowing the truth more than the belief they already know it."
"Making bass is easy, making music is the hard part!"

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post #5 of 34 Unread 05-15-2015, 02:41 PM - Thread Starter
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Made more progress on the Fusion-4 towers.

Here I am just starting the glue up process:


More internal braces going in:


The drill press and a spade bit makes creating the braces pretty quick and easy:


Yay for clamps:
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post #6 of 34 Unread 05-15-2015, 03:10 PM
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Quote:
Originally Posted by the-jessman View Post
Since you asked here are some pics of the subs and surrounds:




The room will definitely be getting some REW treatment when the time comes. I'll be sure to post the results!
Is that the Micro Marty? What wood do you use for the cabinet?
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post #7 of 34 Unread 05-15-2015, 03:39 PM - Thread Starter
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Quote:
Originally Posted by Altheia View Post
Is that the Micro Marty? What wood do you use for the cabinet?
Yup its a Micro Marty, I used 3/4" Arauco plywood for the cabinet. If you are interested I have a bunch of pictures from the build on my facebook page: https://www.facebook.com/media/set/?...9872967&type=3

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post #8 of 34 Unread 05-15-2015, 03:56 PM
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Are those Dayton RSS390HO's in those Micros jess?

Why waste $ on more cheap stuff, it's like challenging a dragon with a pocket knife.
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post #9 of 34 Unread 05-15-2015, 05:25 PM - Thread Starter
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Quote:
Originally Posted by muzz View Post
Are those Dayton RSS390HO's in those Micros jess?
Yes they are.

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post #10 of 34 Unread 05-15-2015, 05:47 PM
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Thumbs up

Quote:
Originally Posted by the-jessman View Post
Yes they are.
I had those on order when they were B.O, I just cancelled yesterday.
Those Model VERY well in a 3.75 Ported(Micro), but I decided to do HT18's in new cabs and PA460's instead(in those Micro cabs).

They look good, bigger/fatter surrounds than it looks online, have you tested them?

Why waste $ on more cheap stuff, it's like challenging a dragon with a pocket knife.
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post #11 of 34 Unread 05-15-2015, 05:53 PM - Thread Starter
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Quote:
Originally Posted by muzz View Post
I had those on order when they were B.O, I just cancelled yesterday.
Those Model VERY well in a 3.75 Ported(Micro), but I decided to do HT18's in new cabs and PA460's instead(in those Micro cabs).

They look good, bigger/fatter surrounds than it looks online, have you tested them?
They are currently being used by my friend and he is very happy with them. I haven't measured them yet, and they are just kinda temporarily setup. They will get the REW/DSP treatment when I get the rest of his gear finished.

"Nothing prevents people from knowing the truth more than the belief they already know it."
"Making bass is easy, making music is the hard part!"

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post #12 of 34 Unread 05-15-2015, 06:01 PM
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Quote:
Originally Posted by the-jessman View Post
They are currently being used by my friend and he is very happy with them. I haven't measured them yet, and they are just kinda temporarily setup. They will get the REW/DSP treatment when I get the rest of his gear finished.
Like I said, they were on B.O when I ordered them, I JUST got the cancel yesterday morning before they came back.
Per WinIsd hey went lower than my MFW15's in the Micros(by like 5hz DOH!), while handling more power.....I just decided on a different direction.
I may regret my decision, but I doubt it....
I'll always keep these in mind though.

Why waste $ on more cheap stuff, it's like challenging a dragon with a pocket knife.
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post #13 of 34 Unread 05-15-2015, 07:05 PM
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Another nice build here!

What's the plan for the tower baffles? Will you modify the diysg baffles or recreate your own?

The towers also appear to have a lot more volume. Did you model the drivers in the bigger cab?
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post #14 of 34 Unread 05-15-2015, 08:33 PM - Thread Starter
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Quote:
Originally Posted by Samps View Post
Another nice build here!

What's the plan for the tower baffles? Will you modify the diysg baffles or recreate your own?

The towers also appear to have a lot more volume. Did you model the drivers in the bigger cab?
I'm going to modify the DIYSG baffles. The CNC cutouts are too good not to use. Its not going to be much of a modification, just some body filler to fill in where the roundover is on the bottom of the DIYSG baffle. I'll take pics when I get to that step.

Internal volume of the cabinets will be the same as stock. There is a solid panel separating the top 2/3 where the drivers are, from the bottom 1/3, which will just be empty space.

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post #15 of 34 Unread 05-15-2015, 10:10 PM
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Good answers!

I had considered modifying my diysg baffles. My plan was to saw off the round over on the bottom edge and butt joint another panel. But I decided to use them as is.

The extra volume might be beneficial. I haven't modeled it, but it's possible that the standard size was chosen for a particular size limitation. Your larger cabs might offer an advantage without the dead space. It might be worth a look. Especially if it's being driven with an avr where the max power handling isn't a concern.
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post #16 of 34 Unread 05-16-2015, 03:42 PM - Thread Starter
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I finished gluing up everything on the cabinet except for the trim pieces:

And my family wonders why all I want for my birthday is more clamps!

Here is what the front of the cabinets looks like after I trimed up the edges, now to deal with that void between the panels:


This is a good job for body filler:

Once it sets up I'll sand everything down flush and profile the edges. You hopefully won't be able to tell the front is more than one panel.

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post #17 of 34 Unread 05-16-2015, 04:04 PM
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Gonna be some LONNNNNG bastards!

Why waste $ on more cheap stuff, it's like challenging a dragon with a pocket knife.
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post #18 of 34 Unread 05-16-2015, 04:28 PM - Thread Starter
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Quote:
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Gonna be some LONNNNNG bastards!
Lol, yeah. I think the picture makes them look longer than they really are. They are 45" tall, the pieced at added under the DIYSG baffle is only 17" long, but it looks almost as long as the 28" DIYSG baffles in the picture.

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post #19 of 34 Unread 05-16-2015, 04:33 PM
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great looking work
told anyone how much you're having ?

DIY FAN Denon X5200 , Emotiva UPA7, for 7.3.4 ATMOS/DSU SHARP 80" LED/LCD
FL/FR: DIYSG Fusion 15's , Center: DIYSG 88 Special , SL/SR: RC3II , SRL/SRR: F-3Towers, TF & TR: SLX
2 30" BF THTLP'S , SUBMAXIMUS, 2 x Inuke6000DSP & 2 driverless LHORN cabs
http://www.avsforum.com/forum/401-di...rs-subwoofers/
www.avsforum.com/forum/155-diy-speakers-subs/1485120-submaximus-large-front-loaded-horn
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post #20 of 34 Unread 05-16-2015, 04:45 PM
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That pic makes them look 6' long!

Why waste $ on more cheap stuff, it's like challenging a dragon with a pocket knife.
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post #21 of 34 Unread 05-17-2015, 12:25 AM - Thread Starter
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Alright here is a better shot that doesn't make they look so tall. I got the body filler sanded down nice and smooth and reprofiled the edges so they all match:


I'm gluing some accent panels on the to sides. These are partially to make them look nice and partially to lower the center of gravity so they will be more stable. I still need to add the base to the cabinets:

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post #22 of 34 Unread 05-19-2015, 08:10 AM - Thread Starter
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Here they are ready for the Duratex:


Freshly sprayed:


Now its on to one of my least favorite parts of the building process, crossover assembly. :-(
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This is a nice project, good job! can't wait to see the end result!

Class A amplifiers & efficient speakers is what I run & DIY :)
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post #24 of 34 Unread 05-19-2015, 03:58 PM
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Look great jess!
Those drivers may be tight with that paint in the recess.

Why waste $ on more cheap stuff, it's like challenging a dragon with a pocket knife.
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I might have missed it somewhere, but I'm wondering what woofers you have in the surrounds... They look similar to some I'd seen before.
On another note those towers look awesome.


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post #26 of 34 Unread 05-19-2015, 11:01 PM - Thread Starter
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Quote:
Originally Posted by muzz View Post
Look great jess!
Those drivers may be tight with that paint in the recess.
They were, it was a pain

Quote:
Originally Posted by yogibare01 View Post
I might have missed it somewhere, but I'm wondering what woofers you have in the surrounds... They look similar to some I'd seen before.
On another note those towers look awesome.
Thanks! They are Dayton DS115-8 mids, for more info see here: http://www.diysoundgroup.com/wavegui...sion4-kit.html


I got both the towers done, still have the center channel to do. Here is a shot of one of the finished towers, and half a cat.

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Nice work!

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Quote:
Originally Posted by the-jessman View Post
They were, it was a pain



Thanks! They are Dayton DS115-8 mids, for more info see here: http://www.diysoundgroup.com/wavegui...sion4-kit.html


I got both the towers done, still have the center channel to do. Here is a shot of one of the finished towers, and half a cat.

YUP !! thats totally a good looking speaker ! Well done !!

Class A amplifiers & efficient speakers is what I run & DIY :)
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Quote:
Originally Posted by the-jessman View Post
Freshly sprayed:
I am getting ready to spray my subwoofers with a HVLP sprayer and was just wondering about the setup that you are using for your spray booth. Is it enclosed on all sides, with only the one output through the furnace filter that is pictured. Is just a standard fan behind that?

Also, I saw some warning on DIY spray booths about the possibility of igniting the paint. Did you have to worry about this with the Duartex? Or with spraying such a small amount is it a non-issue?

Also, any general spray tips?
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post #30 of 34 Unread Yesterday, 08:33 PM - Thread Starter
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Quote:
Originally Posted by bitmap42 View Post
I am getting ready to spray my subwoofers with a HVLP sprayer and was just wondering about the setup that you are using for your spray booth. Is it enclosed on all sides, with only the one output through the furnace filter that is pictured. Is just a standard fan behind that?

Also, I saw some warning on DIY spray booths about the possibility of igniting the paint. Did you have to worry about this with the Duartex? Or with spraying such a small amount is it a non-issue?

Also, any general spray tips?
My spray booth is enclosed on all sides. The filter you see in the picture is one of two outlets. I have one inlet with the fan blowing in. The idea was to slightly pressurize the booth to help keep dust out. I don't know if it actually works that way in practice, but it sounded like a good idea. I've also heard about the possible of spray fumes being ignited. That's another reason why I have the fan on the inlet, there is a shroud that goes over the fan that should make it pretty hard for any fumes to get to it. I only spray water-based stuff in my booth though, so blowing myself up should be a non-issue

As far as spraying Duratex goes, I don't think I'd want to use a regular HVLP gun. This is what I use: http://www.harborfreight.com/1-12-ga...gun-60314.html
It does the job VERY well and for $25 you can't beat the price. You can vary the amount of texture you get by which nozzle you use and how much air pressure you run. Its a pretty flexible system. I've sprayed Duratex on a lot of cabinets with it.

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