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21" Maelstrom Curved Box Build

post #1 of 729
3/27/10 at 11:45pm
Thread Starter 
I started my first DIY sub about 6 weeks ago and I thought I would bring you guys up to date. First off I won this Amazing driver from Exodus Audio and hometheatershack. I wanted to build an encolsure that would emphasize the how big the M-21 is. I started with some design concepts.


Then Kevin sent me the 21" beast and it was a sight to behold.




So I started with a stack of 3/4" sanded pine plywood.
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post #2 of 729
3/28/10 at 12:03am
...the size of that sub is sick! Good luck with the project. Looks fun!
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post #3 of 729
3/28/10 at 12:41am
Thread Starter 
First thing I had to do was get the design off sketchup and onto the wood.


Then I created a template of the basic box.


Next was to cut the different layers of plywood to create the cone shape.





Once all the outside cuts were done I started on cutting out the inside.



Now That the basic shape of the box was complete I had to start refining it. First job was to take down the corners of the plys around the cone. I used a wood chisel to take those down by hand.


That's were I'm at today. The basic shape of my enclosure.




Next step is to glue it all together so I can start the long process of carving down that excess wood where the cone meets the cube and then sanding the whole thing smooth
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post #4 of 729
3/28/10 at 12:49am
I just finished reading your thread over there. Any ETA on completion or when you'll have the driver mounted?

Also, very impressive. That's a lot of work =]
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post #5 of 729
3/28/10 at 12:52am
Damn, that looks good so far. I will definitely be waiting to see how your setup turns out. Looks like a LOT of time, glue, and clamps though... Not to mention saw blades.

I just assembled my 18" LLT, and am overall very pleased with it. I can't imagine what a 21" driver would sound like. Even with a cheap 18" in an 8 cubic foot ported box, and about 400 watts, I get enough output to give me a headache in the low 30 hz range, and enough SPL to make my blinds flutter at 10 hz, and they are in between two sets of well sealed windows.

How big is the box, and it looks like you are going to go with a sealed enclosure, correct? With a driver like that and plenty of power, I wouldn't see a need to go with a ported design, unless your bass crazy like me.
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post #6 of 729
3/28/10 at 12:53am
Thread Starter 
No eta really. Taking off that excess wood where the cone and cube meet is a real unknown. I have to free hand that part of the build with very little room for error. I don't know how hard or easy that will be thus no idea how long it will take. I'm try to keep patient while at the same time very anxious to see what the driver will look like mounted.
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post #7 of 729
3/28/10 at 12:56am
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Quote:
Originally Posted by s_carter View Post

Damn, that looks good so far. I will definitely be waiting to see how your setup turns out. Looks like a LOT of time, glue, and clamps though... Not to mention saw blades.

I just assembled my 18" LLT, and am overall very pleased with it. I can't imagine what a 21" driver would sound like. Even with a cheap 18" in an 8 cubic foot ported box, and about 400 watts, I get enough output to give me a headache in the low 30 hz range, and enough SPL to make my blinds flutter at 10 hz, and they are in between two sets of well sealed windows.

How big is the box, and it looks like you are going to go with a sealed enclosure, correct? With a driver like that and plenty of power, I wouldn't see a need to go with a ported design, unless your bass crazy like me.

The box is going to come in just under 7 cu ft. I'm going to power it with a Behringer EP4000 bridged at 4 ohms. I went sealed because I wanted to keep the box a sane size and do something unique with the shape.
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post #8 of 729
3/28/10 at 12:57am
Sweet looking design, but I don't envy you the sanding and shaping. I'll watch with interest as I have an idea for a trans-lam design with some compound curves too. Muchos pics please.

I presume it's sealed? What's the internal volume?
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post #9 of 729
3/28/10 at 1:12am
I'd suggest a rotary tool and a sanding bit, just take your time.
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post #10 of 729
3/28/10 at 1:18am
Thread Starter 
I've already got the Dremel ready to go
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post #11 of 729
3/28/10 at 1:20am
wow, very impressed, the work so far must have taken a whole lot of time!!, big pile of scrap wood for next winter i bet too
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post #12 of 729
3/28/10 at 1:31am
Thread Starter 
Quote:
Originally Posted by ufokillerz View Post

wow, very impressed, the work so far must have taken a whole lot of time!!, big pile of scrap wood for next winter i bet too

I've put in a lot of hours, and yeah, you might say there's been some scrap



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post #13 of 729
3/28/10 at 5:30am
Wow! You are one dedicated man! I look forward to seeing how this monster looks and performs.
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post #14 of 729
3/28/10 at 6:24am
Looks awesome! I'm sub'd....


dbl
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post #15 of 729
3/28/10 at 7:00am
Nice looking design and cool execution too. Can't wait to see the finished product.
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post #16 of 729
3/28/10 at 7:59am
What do you anticipate the finished enclosure to weigh when finished? Like the others say that is just a sh!t ton of work but should turn out very nice when done. What kind of finish are you planning for it?
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post #17 of 729
3/28/10 at 8:56am
Thread Starter 
First impression is the enclosure would be about 60 lbs, but that's a just a guess. I'm going to use a transparent finish so all the plys show. My plan is to do a french polish, the traditional meathod of finishing piano's and other wood instruments. But, that's a first for me too, so I'll have to do some practicing to see if I can actually do it good enough to do it on the box.
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post #18 of 729
3/28/10 at 10:18am
Corock,

I found you over too. I have just realised you are doing a 21" Maelstrom. I don't know why I thought you were doing a 18" one. Doh! I really can't wait to see the finished thing and with that EP4000 bridged into 4ohms you are really in for a nice treat.

Well done!


cheers

Graham
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post #19 of 729
3/28/10 at 10:36am
unbelievable!
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post #20 of 729
3/28/10 at 11:07am
Damn that is sweet!

I always wanted to do he curved design that way.

Not to mention that I love the pure wow factor that the Mal 21 provides!

Nice!
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post #21 of 729
3/28/10 at 11:44am
Wow, very nice build!

Nice monster sub. Its even bending the heck out of your little stand.



cheers
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post #22 of 729
3/28/10 at 1:53pm
Thread Starter 
I started the gluing process today.

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post #23 of 729
3/28/10 at 2:18pm
Quote:
Originally Posted by corock View Post

I started the gluing process today.


That's gonna be a funny pic in a few days...


dbl
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post #24 of 729
3/28/10 at 3:40pm
Wow man, what an impressive design! Actually, everything is impressive. Amount of work, design, craftsmanship.... WOW!
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post #25 of 729
3/28/10 at 4:26pm
I think you need moar clamps .

I can't even begin to imagine how much of a pain in the butt that must have been to cut. Do I count 30 layers!? Very nice job.
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post #26 of 729
3/28/10 at 4:46pm
someone just raided home depot for clamps =]
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post #27 of 729
3/28/10 at 4:50pm
Neat design.... Why don't you clamp up more layers at a time?
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post #28 of 729
3/28/10 at 5:02pm
So, this is a sealed 21" freakin monster !!! What amp and what EQ, if sealed. What is the volume of the box, so to speak. This looks pretty cool so far. Pics are great.

KG
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post #29 of 729
3/28/10 at 5:07pm
Thread Starter 
Quote:
Originally Posted by Starkiller4299 View Post

I think you need moar clamps .

I can't even begin to imagine how much of a pain in the butt that must have been to cut. Do I count 30 layers!? Very nice job.

The cutting was a bit of a pain, but it was fun watching the shape of the enclosure form. I estimate I cut about 7000 inches with a jig saw. There are 32 layers, makes it 23.5" high x 24" wide x 30" deep.

I'm only gluing one layer at a time because its too hard to get more layers to line up when they start slipping around on the glue.
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post #30 of 729
3/28/10 at 5:09pm
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Quote:
Originally Posted by kgveteran View Post

So, this is a sealed 21" freakin monster !!! What amp and what EQ, if sealed. What is the volume of the box, so to speak. This looks pretty cool so far. Pics are great.

KG

Behringer EP4000 bridged at 4 ohms, BFD 1124p eq, box will come in between 6.5 and 7 cu ft.
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