Strafi Translam FaitalPro Tower Build - Page 2 - AVS Forum | Home Theater Discussions And Reviews
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post #31 of 233 Old 03-25-2017, 07:19 AM - Thread Starter
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Thanks for the comments @Carbon66 I appreciate it!

I'm definitely testing at ever step of the way and making adjustments as I go, if I can do it in one pass it will obvious save a lot of time so that's going to be how I start and go from there, the cutting is definitely easier using the method you described and I'm aware, but will triple the amount of time per layer and considering there are 86+ layers I'm going to use the method that requires the least work to achieve the result.

Fun that you're local, if you ever want to connect I'm up in San Ramon and work in Fremont.

Thanks, stay tuned!

Javad
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post #32 of 233 Old 03-25-2017, 11:37 PM - Thread Starter
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Strafi Translam FaitalPro Tower Build

Got some real work done today, things are coming together!



I started with one of the template styles, I did some experimenting and determined I wouldn't be able to just hog them out due to some Poplar chipout going with the grain, the end grain machines perfectly (mahogany wasn't an issue really). I was really hoping chip out wasn't going to be a problem as the amount of work just increased substantially.

So what I'm doing is screwing the template to the layer, tracing the template in pencil, remove template, rough cut with jigsaw (w/in 1/16-1/8"), screw template back on and then router flush, drill 8 dowel holes, remove template, use sanding block to quickly deburr. Each layer takes about 15 minutes all said and done and there are 86 layers currently in both speakers (I made more layers than that).

Aluminum makes an amazing router template material BTW, holds up so much better than any wood I've used and results in a very smooth finish.

In about 10 hours today I got about 30 layers done, I ended up scrapping 3 so far but those were early sacrifices as I was getting the process figured out. I figure I should have all the layers done routering in the next week.

Template screwed to a layer and trimmed



Flush cut





Drilling dowels



And done





Dowel hole close up



Dowels for a test fit



Stacked with dowels



Each layer weighs about a pound



Thanks!
Javad

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post #33 of 233 Old 03-26-2017, 08:30 PM - Thread Starter
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Strafi Translam FaitalPro Tower Build

Got some more work done today, for about 10 more layers done, I basically have all one one layer style done, I'll spend time this week to get the other style done and I should have all my layers routered by week's end.

One thing I did today is I started working on what I call the "port layers", I'll have 2 3" ports on the back of the enclosure and to do this I'll want a flat area to work with, this I am doing 6 layers towards the bottom of the enclosure with a flat profile along the back, that way I can recess a port receptacle in a flat section. Those layers have his inside back profile:





I will also make the bottom removable to make port tuning easier and to give access to the inside, XO mounting, etc. I will also be doing CLD to the top and bottom of the enclosure to ensure they are well dampened and non resonant. In addition there will be a 1.25" hardwood dowel spine that will connect too and bottom panels as well as connecting to internal brace layers.

Thanks!
Javad
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post #34 of 233 Old 03-27-2017, 02:35 AM
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Right on. Diggin' this thread.
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post #35 of 233 Old 03-27-2017, 11:04 PM - Thread Starter
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Quote:
Originally Posted by Carbon66 View Post
Right on. Diggin' this thread.


Thanks @Carbon66 !
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post #36 of 233 Old 03-27-2017, 11:07 PM - Thread Starter
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Got the second layer template machined yesterday and ready to use:



And spent an hour in the shop tonight and whipped up 4 layers.

Here the layers are stacked showing the alternating pattern:







Javad
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post #37 of 233 Old 03-27-2017, 11:22 PM
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Looking all quiet promising now!!! Truly Great Job.

rgs UpperCut
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post #38 of 233 Old 03-28-2017, 02:14 AM
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Hi Javad

Looking forward to see it all glued up .

Similar construction to a speaker cab & amp case's I built .

Are you going to short dowel section's together or run full length from top to bottom ?

Cheers

Mal

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post #39 of 233 Old 03-28-2017, 08:07 AM - Thread Starter
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Quote:
Originally Posted by Oval56 View Post
Hi Javad



Looking forward to see it all glued up .



Similar construction to a speaker cab & amp case's I built .



Are you going to short dowel section's together or run full length from top to bottom ?



Cheers



Mal


Hey Mal! My alignment pin holes are a press fit so I'll be using .7" long dowel pins that I'm cutting in my chop saw by masking taping 20 4' long 1/4" dowels together and making the cut, I did a test run and it worked well.

Thanks!
Javad
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post #40 of 233 Old 03-29-2017, 10:03 PM - Thread Starter
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Well slowly but surely, I've been doing an average of 10 layers a day this week and I'll have this phase of the project done by Friday. I scrapped 3 layers in the first 10 I did, scrapped 2 more in the next 15 but haven't scrapped any since so I should be about 5-7 scrapped by the time I'm done. And by scrapped I'm talking about anything with a chip that would require any wood filler (being very picky).

Here are all the finished layers so far



And some close up shots







Thanks!
Javad
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post #41 of 233 Old 04-02-2017, 10:16 PM - Thread Starter
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Ok, as promised, all layers compete! (queue angels singing!)



I'll end up with 42 air volume holding layers, one too layer, and 2 bottom layers, one containing a trap door.



The top will be solid mahogany, I did a glue up and to make one bigger piece





After drying I ran it through the sander to make it smooth on both sides, then ran it through the template process, but only for the outside.



Roughed out



And routered



Dowel reference holes only 1/4" deep



The top will feature a CLD treatment and will also tie into internal bracing.

The bottom is 2 layers, one layer will hold the captive nuts, the very bottom layer will hold the trap door and also be a decorative ring to hide the door.

Did a glue up for the nutsert flange, before sanding



After sanding



After templating



Bottom layer done and mocked up



And with door, I'll flush mount Allen screws in that





More to come!
Javad
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post #42 of 233 Old 04-09-2017, 01:14 AM
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Weekend update?
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post #43 of 233 Old 04-09-2017, 08:13 PM - Thread Starter
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Strafi Translam FaitalPro Tower Build

Quote:
Originally Posted by Carbon66 View Post
Weekend update?


You bet!

Well after a fun few days at InDIYana speaker building event, 2 hours of sleep last night and an early flight, I was only able to sneak an hour in the garage this weekend but I'll get s lot more done this week =)

I'm at the point where I'll start assembling layers together permanently, the key here will be adding in my bracing layers making assembly order of operations critical.

One thing that needed to be done was to flush the flat port mounting area, when I routered these layers I didn't have a template to lock in the flat to the other layers, but figured I could just flush them to the shallowest layer later on.







Adding the extra dowel holes to the template was a great call, glad I have them, the layer to layer alignment goes from ok to excellent once all 8 dowels are installed.

More to come!
Javad
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post #44 of 233 Old 04-10-2017, 07:52 PM - Thread Starter
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Got the final template cut on the CNC, this locates all the drivers, sets their flush mount, and additional templates go inside this to accurately cut the driver mounting holes as well as give the router a stable base:
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post #45 of 233 Old 04-10-2017, 11:34 PM - Thread Starter
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Did the first glueups tonight, coming along well!

The layers are aligned with 8 dowel pins per layer, each pin is about .7" long as to not bind up between layers. Since I'll need over 700 of these dowels, I had to come up with a fast and accurate way to cut them.

I started with 10 dowels taped together at a time, subsequent bundles are 20 at a time.





Then it's a matter of giving the cut bundles to my 5 yr old daughter who gleefully unwraps them for me



Dowels are set to the right depth with this jig



First layer ready to go, this is the bottom most layer in the enclosure not including the bottom plate and the trap door layers. This and the next 5 layers will house the ports



Clamped up (note top and bottom pieces are sacrificial clamping fixtures which were 2 reject layers)



And glue wiped away





Clamps removed after setting up for 45 mins



Very nice alignment

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post #46 of 233 Old 04-11-2017, 02:45 AM
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Hi Javad

Excellent work

Did you think about getting the front baffles machined out of alloy ? Then rebate the baffles into the cab's.

Cheers

DIY , Ikea Style
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post #47 of 233 Old 04-11-2017, 07:40 AM
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I don't care how it functions, the inside looks cool. I'd want a clear panel on the top or back so I could see it. I always pay attention to the inside whether anyone else will ever see it or not.

Nice work.
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post #48 of 233 Old 04-11-2017, 08:39 AM
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Hope you built a test box to proof this project before doing all this work!

Should look great with some finish on that wood
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One advantage of changing the interior shape. You will get very close to the rigidity of having the full width of the pieces, but will pick up internal volume. These are going to turn out very nice.
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Thanks guys =)
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post #51 of 233 Old 04-12-2017, 08:52 PM - Thread Starter
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The first "braced module" of layers will be 12 layers, this module will house the horn and the 12th layer from the top will contain the first bracing layer. I am glueing up both modules in 6 layers sub-modules, then gluing those together to make the 1 12 layer module.

Here one 6-layer sub-module going together, with the gluing and dowel placement and clamping each 6 layer sub-module takes about 15-20 minutes





Nice glue squeeze out, what I like to see



Tower fully layered up and ready to start assembly, I moved some layers around from this to break up the color distribution







And approx where drivers will go



Driver test fit, 1/32" clearance between frame and template





Javad
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post #52 of 233 Old 04-13-2017, 12:06 AM
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Great build. You're making excellent progress. Props to ya.
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post #53 of 233 Old 04-13-2017, 08:35 AM - Thread Starter
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Quote:
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Great build. You're making excellent progress. Props to ya.


Appreciate it!
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post #54 of 233 Old 04-13-2017, 08:37 AM - Thread Starter
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Top two sub-modules are finished, the 7-12 module will get a brace, keeping everything labeled and organized is critical



Work on the bracing is coming along nicely. The way I designed the driver spacing, I am able to put bracing layers all in one style of layer, this means I'll need 3 braces per cabinet and I can make a template to easily and accurately router all 6 pieces. Bracing layers are 3/4" 7 layer poplar plywood.

Initially I was able to trace the ID profile right off the template





With template done and fit, it's a quick rough cut on subsequent layers then off to the router table





Test fit







Since I'm using screws to hold to the template I finished the holes off with a 1" F-bit and gave things a nice round over







A 1.5" dowel will run through the center holes and tie all bracing layers together as well as the top and bottom of the cabinet.

Next step is to continue assembling the cabinet in 6 layer sub-modules.

Thanks!
Javad
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post #55 of 233 Old 04-13-2017, 10:25 AM
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UNBELIEVABLE! Fantastic work, cant wait to see these finished up!

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post #56 of 233 Old 04-13-2017, 02:19 PM
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Geez - thats incredible. Great dedication!
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These look terrible. Finish them and send them to me, that way you have these eyesores out of the way. Just kidding, looks good. Will be interesting to see how they perform.
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post #58 of 233 Old 04-13-2017, 03:56 PM
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I thought I would share this. An internal diffuser surface was used by B&W for a while on a lower end model.

http://www.bowers-wilkins.co.uk/Down...info_sheet.pdf

They seem to have abandoned the idea. May not have worked well or may have just been too expensive. If it was combined with some damping I would imagine that it might help reduce reradiation through the driver. When you break the wave each new path carries less energy and is thus more easily absorbed.


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post #59 of 233 Old 04-14-2017, 09:43 PM - Thread Starter
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Made some great progress today, things are really coming together (literally)

I now have all 6-layer sub-modules glued up, that means I have 7 per cabinet, and will glue up all 7 modules at the same time. The reason for this is that the 6-layer module remains somewhat flexible and compliant, more layers that that becomes stiffer and the last thing I want are gaps between layers.



So now onto some detail work, the port module. Because I'm crazy and want to be able to remove the ports to ease tuning, I am making an easy to remove module, this also gives me access to the inside of the enclosure through the trap door should I ever need it.

See steps below, should be self explanatory:



















Dowels will locate the port module so the ports line up accurately, two large screws will hold the mode to the enclosure





Dowels glued into the port module base only





Time to dry



More to come!

Javad
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post #60 of 233 Old 04-14-2017, 10:05 PM
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These are looking amazing!


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