I've started a long delayed project to build new surrounds. My first post here on this subject was back in 2010. I move slow sometimes. I finally decided on Wayne Parham's 2 pi design, a bass reflex two way. The cabinets are about 15 x 21 x 8. Details here
The drivers are an Eminence Alpha 10 midwoofer and a Vifa DX25 tweeter.
I haven't taken too many pictures so this will be brief.
Here's the result of two days of making sawdust. All of us were worn out.
I built the boxes out of some incredibly crappy import plywood that I have in stock. The panels are not flat by any stretch of the imagination. Also the veneer peels off like cheap shelf paper or something. The core is structurally sound though. I laid out all the joinery to avoid gluing anything to the face veneers. All the joints are simple rabbet cuts about 1/8" deep. The edges are getting a 3/4" roundover and then will get a liberal coat of Duratex. I haven't decided if I'm going to use grills or not. Likely will not. Here's a couple of shots of the boxes.
Nice void there, 'eh? That joint needs a bit of sanding flush before I attach the baffle too.
Rear corner after some sanding. I blew right through the veneer in places but the Duratex will cover a multitude of sins. I'll fill the voids with rock putty.
Simple terminal cups from P-E. I used the same ones on my subwoofer project and the quality is good.
Here's the boxes lined up in various stages of stuffing. They get the pink stuff on the back, bottom and port side. I used rigid insulation on the box furthest to the right but ended up ripping it out. Didn't want to deviate too far from Wayne's plans, which specify R-11 or R-13 fiberglass.
Here's a baffle and test-fit of the port. The port material comes from the place with the ez button (Staples). The little mouse ear cutouts in the tweeter hole are for the terminals. Clearance is tight.
A baffle shot with the drivers laid into place.