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DIY speaker grill build....MY FIRST!!

post #1 of 20
Thread Starter 
These are for my RB kit but I have to build more for the rest of my speakers.

I was always unconfortable in doing it because I thought they would suck....they are okay!

Here are pics of the steps

1. cut 2 8x12 sections out of 1/2 MDF


2. Round over the edges with a 1/4 roundover bit.


3. Measure 1/2 inch inside border then drill holes around the inside to help with cutting


4. Using the holes as starting point cut out the frame




5. Paint black


6. Using 77 3M spray adhesive, spray both sides, wrap cloth around, cut cloth.




THought I would share my first attempt. Im happy I did it!
post #2 of 20
That looks nice. What are your plans for attaching to your speakers?

I actually just finished building the frames for my grilles, so this is good timing. I used 1x2 oak and put 45 degree clipped corners on it. I'm going to countersink magnets to attach it to the boxes. I'll get pics up this eve...

Jason
post #3 of 20
Thread Starter 
Quote:


That looks nice. What are your plans for attaching to your speakers?

I actually just finished building the frames for my grilles, so this is good timing. I used 1x2 oak and put 45 degree clipped corners on it. I'm going to countersink magnets to attach it to the boxes. I'll get pics up this eve...

Jason

Nice, please post pics.

I just ordered lots of different magnets from http://www.rare-earth-magnets.com/

So far I will glue the small disc versions to the grills and then drill screws (hex heads) into my speakers

I know I should have measured and drilled the screws in before the finish but I was too impatient so I will have to fix any problems afterwards.



This was my first try so I can only get better at it
post #4 of 20
Yeah...I know the learning curve well.

I plan to drill holes into the faces of my grille frames and sink the magnets in from the front so that there's approx 1/8" or so behind the magnet and then cover the hole in the front with an oak plug before covering it with cloth. I wish I had done the same with the front baffle, but I'll end up sinking the magnet into the face and then covering with a thin plug and hope that it holds well enough.

Jason
post #5 of 20
Thread Starter 
Quote:


I wish I had done the same with the front baffle, but I'll end up sinking the magnet into the face and then covering with a thin plug and hope that it holds well enough.

I will also be recessing the magnet discs into the grill corners...of course I have to lift the fabric that I glued EARLY.

I havent figure the best way to handle the baffles when Im just staining my speakers. With laminate or paint its definitely easier.

So for now I will have the screws heads sitting out on the baffle face. I have seen that in comercial designs, its not that bad.
post #6 of 20
Those rare earth magnets have great power!
Invisible.

I used them on my screen for manual masking, and my subwoofer for to-be-made still grille:



btw, neat to see different ways to make speaker grilles.


penngray, I see how you used a roundover bit on MDF, I did that for my basic AV closet back doors and found the router cut induced stress onto the MDF and it warped slightly over time, hopefully yours does not show that. A noob mistake, that's why the pros make panel doors for no warpage, mine work for now, slight but you can see it.
Seen from adjoining rec/play room:
post #7 of 20
Yeah, I had considered using Birch ply for my grilles, but was worried about warping/twisting over time. The magnets that I bought (PE) are a bit larger than 3/8", so I'll have to pick up a 13/32 or 25/64 bit.

Jason
post #8 of 20
Thread Starter 
Quote:


penngray, I see how you used a roundover bit on MDF, I did that for my basic AV closet back doors and found the router cut induced stress onto the MDF and it warped slightly over time, hopefully yours does not show that.

That could happen, I will definitely learn from it.
post #9 of 20
I order my magnets from here usually: http://www.kjmagnetics.com/proddetail.asp?prod=DC2. They are a bit more expensive but they sell much bigger magnets, and they are higher grade.
post #10 of 20
Quote:
Originally Posted by JasonColeman View Post

...so I'll have to pick up a 13/32 or 25/64 bit.

Never mind...our woods teacher had both, so I'm back in biz!

Jason
post #11 of 20
Always made grills out of high quality ply, I don't think mdf is up to it for the narrow sections a grill presents.
The magnets from PE are good also. Four of them hold the grill on a thumping maelstrom no problem.
post #12 of 20
Have you guys ever thought of installing the magnets from behind the front baffle before assembling the cabinet? I am planning on doing this when I build my recession buster speakers. It will clean up the front of the baffle with no extra holes to fill in.
post #13 of 20
Quote:
Originally Posted by tsloms View Post

Have you guys ever thought of installing the magnets from behind the front baffle before assembling the cabinet? I am planning on doing this when I build my recession buster speakers. It will clean up the front of the baffle with no extra holes to fill in.

That's exactly what I would do next time...I'd countersink the magnets into the front baffle from behind or simply sink them behind a veneer if I used ply for the front baffle.

I just got my magnets installed in the grille frames and the holes plugged. I also got the outside edges of the frames rounded over. Once I get the plugs trimmed, I'll get the fabric installed.

Jason
post #14 of 20
Thread Starter 
Quote:


Have you guys ever thought of installing the magnets from behind the front baffle before assembling the cabinet? I am planning on doing this when I build my recession buster speakers. It will clean up the front of the baffle with no extra holes to fill in.

Good point, too bad I never think of it all UNTIL after I have it stained in ready

I have ported boxes coming for my 2nd RB kit so I will do that with those.

I wonder if I can glue STRONGER magnets to the inside of the baffle and it would work through the 3/4 birch? Time to test!
post #15 of 20
That would have to be a pretty strong magnet to hold securely through 3/4" material. You have to keep in mind that the "shear" strength of magnets isn't nearly as powerful as their "pulling apart" strength...and yes, those are the technical terms!

Jason
post #16 of 20
The magnets are all under the veneer on all these speakers.

Just drill, shove, and a little bondo over the top. Then veneer over all of it.
post #17 of 20
Thread Starter 
Quote:


Just drill, shove, and a little bondo over the top. Then veneer over all of it.

Im not a veneer kind of guy
post #18 of 20
Well, paint would work just as well.
post #19 of 20
Thread Starter 
Quote:


Well, paint would work just as well.

I know, I know...painting, veneering.....makes things easier. Im just a big natural wood guy and it takes less time for me. its totally a personal choice, never had great experiences with other appoarches except laminating my sealed subs but even then I placed wood trim on the edges to hide the flaws
post #20 of 20
Well, at least it was real wood veneer....Takes a stain nice.
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