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MFW-15 sealed (x4)

post #1 of 101
Thread Starter 

I finally got started building some plywood boxes for the things in these cardboard boxes. Muchas gracias to Erich.
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Edited by petew - 6/16/12 at 12:00pm
post #2 of 101
/rubbing hands together excitedly

Can't wait for more pics!
post #3 of 101
Thread Starter 

I started with the top, bottom and sides. Material is 3/4" AraucoPly.
One box on the floor, another on the bench, number three in clamps, four leaning on the doghouse waiting to be assembled.

 

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Edited by petew - 6/16/12 at 12:04pm
post #4 of 101
Thread Starter 

Can't have too many clamps.

 

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Edited by petew - 6/16/12 at 12:04pm
post #5 of 101
Thread Starter 

Another view. Helpers are hanging in the shadows.

 

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Edited by petew - 6/16/12 at 12:05pm
post #6 of 101
Thread Starter 

I cut dados in the top and bottom pieces and along the front and back of all four sides (to receive bracing). Dados make assembly so easy - no nails or screws, just Titebond II wood glue. Bessey K body clamps are a wonderful piece of engineering.

 

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Edited by petew - 6/16/12 at 12:05pm
post #7 of 101
Thread Starter 

Closeup of the dado

 

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Edited by petew - 6/16/12 at 12:06pm
post #8 of 101
Thread Starter 

Number four in the clamps.

 

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Edited by petew - 6/16/12 at 12:07pm
post #9 of 101
Thread Starter 

Bracing the corners. I nailed plywood triangles into the dados. I had to clamp one box corner-to-corner to square it up. All the others were within 1/16" on the diagonal measurements.

 

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Edited by petew - 6/16/12 at 12:08pm
post #10 of 101
Thread Starter 

Closeup of the corner braces. I'll eventually glue the front and back baffles to these braces.

 

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Edited by petew - 6/16/12 at 12:08pm
post #11 of 101
Thread Starter 

Another closeup. Dado is ready to receive the corner brace.

 

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Edited by petew - 6/16/12 at 12:09pm
post #12 of 101
Thread Starter 

Before I nailed the braces in I pulled them tight to the corner with a clamp. That forced the warped plywood flat and made the corners square.

The pocket holes don't have any function in these boxes. The braces were cut out of left over scraps from my oak coffered ceiling project.

 

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Edited by petew - 6/16/12 at 12:10pm
post #13 of 101
Thread Starter 

Big stack of braced boxes.

 

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Time for a Samual L. Jackson.


Edited by petew - 6/16/12 at 12:10pm
post #14 of 101
Thread Starter 

I made a quick and dirty jig to nail up braces. I just used the finish nailer to attach wood scraps to the bench top.

 

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Edited by petew - 6/16/12 at 12:13pm
post #15 of 101
Thread Starter 

Here's a brace in the jig, freshly nailed.

 

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Edited by petew - 6/16/12 at 12:12pm
post #16 of 101
Thread Starter 

A few braces made and a stack of sticks in line for glue and nails.

 

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Edited by petew - 6/16/12 at 12:13pm
post #17 of 101
Thread Starter 

Finished braces ready to install in the boxes.

 

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Edited by petew - 6/16/12 at 12:13pm
post #18 of 101
Thread Starter 

Closeup of bracing. X marks the bottom.

 

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That's all I got done on day two. Must have been the Samuel L. Jacksons.


Edited by petew - 6/16/12 at 12:14pm
post #19 of 101
Thread Starter 

Day Three...
More bracing. I installed four more sticks to brace the middle of the panels. I cut the ends at a 3 degree angle so I could tap the sticks into place without bowing the panels out. I didn't nail the ends but the braces are nailed together at the intersection. I've got gobs of glue everywhere.

 

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Edited by petew - 6/16/12 at 12:14pm
post #20 of 101
Thread Starter 

More bracing. I've added more sticks to connect the first set of braces to the cross braces. Are we done yet? I think so....

 

IMG_0297.jpg


Edited by petew - 6/16/12 at 12:15pm
post #21 of 101
Thread Starter 

Test fit. The driver is sitting on the brace in this shot. The back of the speaker will be about 1/4" from the brace once I have the baffle mounted.

 

IMG_0299.jpg


Edited by petew - 6/16/12 at 12:15pm
post #22 of 101
Thread Starter 
Next steps....
Rough sanding of the rabbit joints.
True up the edges where the front and rear baffles go. (mostly clean up glue squeeze out).
Do a round-over on the corners.
Fabricate baffles - I have a sheet of Chinese birch plywood for baffles.
post #23 of 101
very nice work Pete...
Are you going to stuff your cabs with polyfill?
post #24 of 101
Thread Starter 
Quote:
Originally Posted by Fatshaft View Post

...Are you going to stuff your cabs with polyfill?

What's the general consensus about stuffing? I've heard it makes the cabinet model slightly larger. Any other audible effects? This is my first speaker construction project so any suggestions are welcome.
post #25 of 101
Just a heads-up, if you haven't already, take those woofers out of the box. I noticed, with mine, when boxed up, the surrounds push up against the cardboard, which forces the cone in a little. After being boxed up for a while, I noticed my woofer cones, at rest, settled in (towards magnet) from center. If you can, have them in a down firing situation/position for a while so gravity will help push those cones back to rest in the center of their stroke.
post #26 of 101
Thread Starter 
Thanks for the heads-up Looney. I'm off to the Big Orange Box for tee nuts and a new router bit...
post #27 of 101
All looking good. Seems like a LOT of bracing; at least you know those boxes won't be going anywhere!

Depending on how much power you're giving each, and how hard you're driving them, AIUI, stuffing a pillow or two in each will help with efficiency, but might make you reach xmax a little sooner (higher up in frequency).
post #28 of 101
Thread Starter 
I'll be driving them with a BK 5000 series II five channel amp rated at 145 into four ohms.

I think I'll run them unstuffed to start. I'm not going to do any wood finishes right away - can always stuff later when I take the drivers out to finish the cabs.
post #29 of 101
Thread Starter 
Quote:
Originally Posted by nube View Post

...Seems like a LOT of bracing....

OCD on display. I kept adding sticks until the "rap test" gave a consistent sound everywhere. I'll calculate internal volume now that the bracing is in place.
post #30 of 101
Nice work,I see your're well equipped.What are you gonna power them with?
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