Jk's 1099 build thread - AVS Forum | Home Theater Discussions And Reviews
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post #1 of 80 Old 08-23-2017, 06:24 PM - Thread Starter
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I picked up a set of components without cabs for a pair of 1099's, and an unbuilt, unopened horizontal center channel. This will be my next project. I contacted Erich to get the rest of the things I needed for this build. Three flat packs, new gaskets and screws for the once built pair, and two new baffles. He came through in classic DIYSG style. I love that shipping from there to SE MI is basically overnight. So I have my boxes to build, and the rest is in route. I'm going all out here. I've always wanted to build a nice set of speakers that sound great but also look great. I'll be asking questions about veneering cabs, and building grills with hidden magnetic attachment points under the veneer. I think I have a good idea where to start, but it's my first attempt at veneering, and making a speaker look good. Any thoughts and tips appreciated! This is a 'side project' so it's going to take a long time. I'll most likely use these for my living room setup. I'll post a pic of the veneer I chose.
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post #2 of 80 Old 08-23-2017, 09:35 PM
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I built a LCR set of 893s recently. I'd be glad to share the things I learned in the build. The veneer can be easy, as long as you take the right steps..

I'll watch your thread and chime in when you get to each stage.
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post #3 of 80 Old 08-24-2017, 03:45 AM - Thread Starter
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I built a LCR set of 893s recently. I'd be glad to share the things I learned in the build. The veneer can be easy, as long as you take the right steps..

I'll watch your thread and chime in when you get to each stage.
Did you veneer the baffle as well? The cutouts on the front look difficult.
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post #4 of 80 Old 08-24-2017, 07:27 AM
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Did you veneer the baffle as well? The cutouts on the front look difficult.
I veneered the baffles on my 1299's See this post here: Custom Maple Veneered Agressive 1299 Vented LCR Build

I got a "laminate trim bit" at the local home improvement store. I used that for the cutouts only. I used a "flush cut bit" to trim the veneer along the sides of the cabinet.
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post #5 of 80 Old 08-24-2017, 07:44 AM
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Veneer is actually pretty easy. I put up some photos and explanation in my build thread and am happy to help.

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post #6 of 80 Old 08-24-2017, 08:12 AM - Thread Starter
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Thanks for the info so far guys. I know once I get into it, I'll have more questions. I'll keep reading and planning.
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post #7 of 80 Old 08-24-2017, 08:56 AM
 
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post #8 of 80 Old 08-24-2017, 09:52 AM
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I did not veneer the baffle, mainly because I built grill covers. I also didn't know about the laminate trimmer that jehlinge mentioned above. When I built my 893 towers, I wanted the horns located at the top, so I ended up cutting the top woofer off, and grafting it below the other woofer. I did a build thread on the DIY Sound Group site, titled something like "Frankenstein 893 towers" Anyway, it was a nice project.
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post #9 of 80 Old 08-24-2017, 10:19 AM - Thread Starter
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post #10 of 80 Old 08-24-2017, 10:21 AM - Thread Starter
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I did not veneer the baffle, mainly because I built grill covers. I also didn't know about the laminate trimmer that jehlinge mentioned above. When I built my 893 towers, I wanted the horns located at the top, so I ended up cutting the top woofer off, and grafting it below the other woofer. I did a build thread on the DIY Sound Group site, titled something like "Frankenstein 893 towers" Anyway, it was a nice project.
I've seen your build. Awesome work. I thought the baffles would come with a large roundover. But they came square and that I like. So I will veneer everything.
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post #11 of 80 Old 08-24-2017, 10:23 AM - Thread Starter
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Quote:
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Did you veneer the baffle as well? The cutouts on the front look difficult.
I veneered the baffles on my 1299's See this post here: Custom Maple Veneered Agressive 1299 Vented LCR Build

I got a "laminate trim bit" at the local home improvement store. I used that for the cutouts only. I used a "flush cut bit" to trim the veneer along the sides of the cabinet.
I will be reading your thread when I have a chance to give it the attention it deserves. Awesome work. Your cabs are the look I'm going for. Except I bought a laminated product. Not real wood. Don't tell anyone.
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post #12 of 80 Old 08-24-2017, 01:21 PM
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if you need crossover pcbs let me know. I believe I have a set of 3left.
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post #13 of 80 Old 08-24-2017, 01:27 PM - Thread Starter
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if you need crossover pcbs let me know. I believe I have a set of 3left.
Thanks, but I have them.
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post #14 of 80 Old 08-25-2017, 04:01 AM - Thread Starter
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Hey @jehlinge
Can you expand on exactly what router bit you used and the process to laminate your baffles? I've done a quick search for a laminate bit and can't really figure it out.
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post #15 of 80 Old 08-25-2017, 05:12 AM
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Originally Posted by Jk7.2 View Post
Hey @jehlinge
Can you expand on exactly what router bit you used and the process to laminate your baffles? I've done a quick search for a laminate bit and can't really figure it out.
This is the bit I used for the solid walnut that I used on my 1099 baffles. Worked perfect, even for the super shallow midrange recesses.

https://www.whitesiderouterbits.com/...products/sc28c

I also have this one, but the rounded tip is too long for very shallow recesses.

https://www.amazon.com/Bosch-85285M-.../dp/B0009H5M3O

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post #16 of 80 Old 08-25-2017, 08:57 AM - Thread Starter
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Hey @jehlinge
Can you expand on exactly what router bit you used and the process to laminate your baffles? I've done a quick search for a laminate bit and can't really figure it out.
This is the bit I used for the solid walnut that I used on my 1099 baffles. Worked perfect, even for the super shallow midrange recesses.

https://www.whitesiderouterbits.com/...products/sc28c

I also have this one, but the rounded tip is too long for very shallow recesses.

https://www.amazon.com/Bosch-85285M-.../dp/B0009H5M3O
Thank you. I will grab one of those.
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post #17 of 80 Old 08-25-2017, 10:38 AM
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Hey @jehlinge
Can you expand on exactly what router bit you used and the process to laminate your baffles? I've done a quick search for a laminate bit and can't really figure it out.
I used the bit mentioned earlier in this thread.

https://www.amazon.com/Bosch-85285M-.../dp/B0009H5M3O

It worked fine for my 1299's...but just barely. The other one mentioned by @dtsdig might be a better option.

You just apply veneer like you normally would to the baffle. Be careful pressing it down around the cutouts....you don't want to press though a cutout void and "crack" the veneer when applying. Then I just used a utility knife to make a cut through the veneer in which I could insert the laminate bit and trimmed away..easy peasy.

I only used this bit for the cutouts. All of the other cabinet edges I used a flush trim router bit with a bearing. Since the laminate bit lacks the bearing, I was afraid it would damage the veneer on the opposite face to what I was trimming.

One last piece of advice...make sure you check all the woofers and mids for fit after trimming the veneer and BEFORE you apply your finish. On the 1299's, the cutouts for the woofers are pretty tight. The laminate bit leaves just a bit of extra veneer...maybe 1/64". None the less, the woofers would no longer go in...so I had to do some gentle hand sanding to get them in there. You will want that done before you stain and finish.
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post #18 of 80 Old 08-25-2017, 10:58 AM - Thread Starter
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Quote:
Originally Posted by jehlinge View Post
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Originally Posted by Jk7.2 View Post
Hey @jehlinge
Can you expand on exactly what router bit you used and the process to laminate your baffles? I've done a quick search for a laminate bit and can't really figure it out.
I used the bit mentioned earlier in this thread.

https://www.amazon.com/Bosch-85285M-.../dp/B0009H5M3O

It worked fine for my 1299's...but just barely. The other one mentioned by @dtsdig might be a better option.

You just apply veneer like you normally would to the baffle. Be careful pressing it down around the cutouts....you don't want to press though a cutout void and "crack" the veneer when applying. Then I just used a utility knife to make a cut through the veneer in which I could insert the laminate bit and trimmed away..easy peasy.

I only used this bit for the cutouts. All of the other cabinet edges I used a flush trim router bit with a bearing. Since the laminate bit lacks the bearing, I was afraid it would damage the veneer on the opposite face to what I was trimming.

One last piece of advice...make sure you check all the woofers and mids for fit after trimming the veneer and BEFORE you apply your finish. On the 1299's, the cutouts for the woofers are pretty tight. The laminate bit leaves just a bit of extra veneer...maybe 1/64". None the less, the woofers would no longer go in...so I had to do some gentle hand sanding to get them in there. You will want that done before you stain and finish.
Great advice thank you. My veneer is a laminate product, so it's pre finished. That should save me a little. I had time last night to glue up the first flat pack, but I didn't. I got lazy.
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post #19 of 80 Old 08-25-2017, 11:46 AM - Thread Starter
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I found the router bit on amazon. Thanks for the help.
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post #20 of 80 Old 08-27-2017, 06:50 AM - Thread Starter
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How much denim insulation should I install per compartment? I'm assuming in the woofer compartments just the sides and bottom is enough? I know to stay away from the ports. How about the midrange compartment? Stuff it on every surface? Any advice / knowledge appreciated.
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post #21 of 80 Old 09-04-2017, 09:13 AM - Thread Starter
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Making slow progress on my 1099's. My laminate showed up. No idea how I'll cut it into manageable pieces. Maybe I'll try our aluminum sheer at work. It sheers aluminum up to .063 thick. So maybe it will handle this product. I'm just nervous about chipping and cracking. First box is all glued up and ready for sanding. Cutout for terminal cup is done and crossover installed and wired. I'm happy I tested a hole saw and my router with the right bit and I can flush mount my terminal cups. I'll probably get all three boxes to this point and then sand and veneer.
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post #22 of 80 Old 09-04-2017, 01:02 PM
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The cabinet looks great you lined the inside of the cabinet right the only thing I've seen differently is guys using poly fill for the mid and cd section of the box but I don't see any problems using the denim insulation. I can't wait to see how these are going to look with the laminate on the boxes.
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post #23 of 80 Old 09-04-2017, 04:43 PM - Thread Starter
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The cabinet looks great you lined the inside of the cabinet right the only thing I've seen differently is guys using poly fill for the mid and cd section of the box but I don't see any problems using the denim insulation. I can't wait to see how these are going to look with the laminate on the boxes.
Thanks. I read in a few places that the denim insulation works for the cd mid section and the ported woofer sections. I hope it is good. I'm still wondering how to route out and trim the veneer around the baffle openings. The woofers are set in 5/16 or so, but the mids are hardly an 1/8". See my pics with the bit that I bought for this part. Doesn't look like it will work.
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post #24 of 80 Old 09-09-2017, 11:27 AM - Thread Starter
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Change of plans
I couldn't live with the laminate I chose. It was too shiny and cheap looking. So I just ordered real wood veneer and decided to duratex the baffles. I like the look of black speaker fronts and wood veneer sides and back. I'll just have to put in the work staining and finishing the cabs. It will be worth it in the end. Any suggestions on a stain and matte finish clear coat product and or application methods please share.
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post #25 of 80 Old 09-09-2017, 01:18 PM
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sounds like a nice choice - which type of veneer? I used 5 coats of pure tung oil, put on with a rag https://www.woodcraft.com/products/w...tung-oil-quart

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post #26 of 80 Old 09-09-2017, 01:26 PM - Thread Starter
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sounds like a nice choice - which type of veneer? I used 5 coats of pure tung oil, put on with a rag https://www.woodcraft.com/products/w...tung-oil-quart
I just ordered 4 rolls of parts express walnut veneer. Tung oil? I have heard of it. But I want to go dark with the finish. How dark will tung oil get? Do you have a pic of your finished cabs?
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post #27 of 80 Old 09-09-2017, 02:39 PM
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That's five coats dry close up, with a bit of glare from a nearby window.

And here's a comparison before and after one coat, still wet.



And 5 coats from a distance:

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post #28 of 80 Old 09-09-2017, 03:06 PM - Thread Starter
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Wow! Those are fantastic. Beautiful. You wouldn't happen to have a pic before any tung oil went on?
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post #29 of 80 Old 09-09-2017, 04:42 PM
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Thanks. The second pic has no oil on the left half. here are another couple of the veneer as received. It is bubinga from gl veneer




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post #30 of 80 Old 09-09-2017, 05:20 PM - Thread Starter
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Thanks. The second pic has no oil on the left half. here are another couple of the veneer as received. It is bubinga from gl veneer



How did you sequence your finishes? Veneer then paint the baffle? How did you trim your veneer? I plan on using my flush trim bit. Good idea? Bad idea? I can get a down cut spiral bit too. Then with contact cement, I assume you can only do one panel a day right? Sorry for all the questions. I've never done any speaker finishing at all. Other than flat black paint.
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