Nice build thread, great workmanship, and you are pulling this off with a circular saw - awesome!
Thanks! Considering this is my second DIY project with wood, its going good so far. Reading everyone's build thread here at AVS and watching lots of home improvement shows also helps.
3/19/2013: Final cabinets glued up!
Surround sides glued up and the top/bottoms on the last SEOS cabinet done.
Looks like the fun part is next... Cutting all the EXCESS overhang with the circular saw or jig saw. Then flush trim the edges. I did weigh one of the SEOS cabinets and its 28lbs. Once I add everything I'm guessing its going to weigh 50lbs.
3/20/2013: Crossover time!
I separated the Woofer and CD crossover. Each board measures 4.5 x 7.5" and is 1/8" MDF. You can get a 2x4 sheet at Home Depot for less than $4.
I hot glued everything down but did not have time to solder the connections. Only made 1 board so far, took me about an hour and a half to figure everything out and glue it down.
3/23/2013: It has to be done!
Took me about 4.5 hours to flush trim 3 cabinets. Ugh! Flush trimming the surround baffle had me stumped. I was thinking of making a custom base for the router but that probably would have taken me all day. What I ended up doing was tilting the router by hand, that was fun! There was a few times the router kicked back but I could not let fear stop me. I took it 1/4" at a time and I was able to do it. All 3 cabinets came out real nice, I was surprised. The seams are all uniform and glued nicely.
Some chip out and dents but no big problems.
Tomorrow I plan to flush trim the last two SEOS cabinets and probably round over the edges.
3/24/2013: So close... I can almost hear them.
Finished the sanding, round overs, and some bondo work. The round overs really make the speakers look nice.
For the surround baffle (Top/Bottom) I had to manually create a round over using my orbital sander. Came out fine.
Looks at these beauties, LOOK AT IT!
I'm soldering the crossovers now and plan to put a coat of primer on the SEOS cabinets tomorrow. In case anyone was wondering, I used about 45 oz of PL Premium for the 5 cabinets. I went a little crazy on the glue so I could have used a lot less.
3/26/2013: Love the smell of oil based primer in the morning.
Using this primer: Kilz Original 1QT.
After I put the primer on, I can start to see all the imperfections I could spend weeks getting everything perfect but I'm at the stage of the build where I don't even care anymore lol. I want them in my living room ASAP! I got two coats on today and plan to do another two tomorrow. So far I'm almost done with 1QT of primer. I don't have any paint brushes to do the speaker holes, I was thinking of using a napkin and smear a light coat of black oil based paint that I have. Its going to be covered with the speakers so it doesn't need to look pretty.
I was reading that if you soak the roller in paint and wrap it up tightly that it will last 24 hours. I have enough rollers so this is just an experiment, if it works then great! Saved myself a roller.
Lots of saran wrap and some zip ties at the ends.
3/28/2013: Almost done!
Wrapping the roller in saran wrapped worked! It was still moist and applied the paint just like a new one.
I was expecting the paint to be smooth but ended up with some texture which I really like.
I found some flat black spray paint which I ended up using for the speaker holes.
All 5 speakers.
I finished the crossovers, ready to be wired up to the speakers and terminal.
Tomorrow I plan to put another 2 coats of black paint then Saturday I will set them up. Right on schedule!
I think the internal volume was between 0.4 and 0.5 cu ft after driver volume. In my first post you can download the Google Sketchup file for the surrounds. Just know that the baffle is a lot larger than it should be. I dont think i fixed it in the file i uploaded. The angle of the baffle is 15 degrees.
I actually finished on 3/30/13 but was too busy to post the final pics and tired! It was a workout.
I used industrial strength velcro to attach the crossover boards to the cabinet, one in each corner.
The boards in its final resting place. Also showing the insulation I used, R13. I removed the backing and split it in half. Use 3M adhesive to adhere it to the cabinet.
Now that I'm looking at this picture, I should have used zip ties to tie those wires in the middle... Oh well.
This is the terminal plate I used for all 5 speakers. I could have flush mounted them but didn't feel like doing it. This pic also shows the texture of the paint, pretty cool.
The CD is pretty well protected but the woofer is out in the open. I decided to use the same method as my subs. Cover the waffle style grill with cheap partsexpress cloth. The grill and clamps fit nicely around the woofer.
Shot of the front, not a great picture. I used a flush trim bit and sanded the edges but you can still see the seams in direct light. Who cares, its not visible in the living room unless you inspect them up close.
Final resting place of the 3 speakers. That is a 47" tv.
Couple shots of the surround. I used a keyhole mount on the rear of the cabinet and a A66 Simpson Strong-Tie on the bottom. The keyhole screw is in a stud as is the strong tie. I used two screws to hold the cabinet into the strong-tie. That thing ain't moving!
The SEOS cabinet ended up weighing 52lbs and the Surround at 20lbs IIRC.
My listening impressions... clean. I don't think there is any other word to describe them, is clean. I watched a couple movies, God Bless America and Sinister. I did not have my surrounds up during Sinister. That movie had a great soundtrack too :( . I also didn't have Audyssey setup at the time... The thing about these speakers that I love the most is the dialogue, its so clear and clean.
I was able to do one position yesterday with Audyssey and it set the crossover like this
I was surprised that it actually went that low. I ran it twice just to make sure a train wasn't passing by or something, I live right near the tracks. I did raise the center and front to 80hz. I still need to setup rew and check out my response from 20-120hz before and after Audyssey. Another good thing is that the SEOS speaker trim levels are within 0.5db of the surrounds! So the one pi is a pretty good match sensitivity wise in my listening space.