Having a living room double as your home theater requires some compromises, my compromise is to build smaller yet effective subs. I had a Mirage SUB-8 in the family room that blew the amp, time to build another sub with the 1260 driver and move the PL-200 into the family room.
Decided on ~2.6ft^3, tuned to ~25Hz according to WinISD (have my first 1260 build handling the stuff down to ~18Hz). Already had an nu1000DSP with a free channel, so off to HD for MDF.
Initial cuts (box is 17Wx19Hx20D, 10x"1.5"x24" port):
For anyone new to working with MDF, it's nasty stuff. Wear a mask!! Recommend cutting outdoors if possible. This filter was brand new before I started cutting:
Built the port bottom and notched the inner baffle to go around it, just like the DIYSG flatpacks (OK, minus the CNC precision!
Inner and outer baffles with their holes cut (plunge router), a 1/4" round over on the outer edge, and a quick shot of black from a rattle can:
My Puma 1/4" crown stapler from Builder's Square (anyone remember them?) finally gave up the ghost, so 1-1/4" brads instead. And a little caulk once assembled (OK, copious amounts of caulk. I miscalculated the gun's ability to get into the seams with the port in position, just smeared it in place with my finger):
Cheap mattress topper from Kmart, used electric stapler to fasten:
Baffles in place, temporarily place driver to pre-drill mounting holes. Some scrap laminate pieces to center it on the outer baffle hole:
Hogged out the port front with a flush trim bit, shot it with black and attached top:
Rounded over outside edges, filled seams and nail holes with wood filler, sanded with random orbital. Did I mention MDF sucks to work with? Wear a mask!!
Restore 4x. Never worked with anything like it before. Crazy thick, great at covering up those little imperfections. Had to get it mixed black here, only tint base available and limited color selection. Don't know if that's the case in other areas. Used a 9", 3/8" nap roller:
Well, maybe not all
those little imperfections. In position you can't see the seams at all, but here you can. This is the end result after 2 coats, also note the texture with the cheap roller cover (also looks more like grey in this pic, but it's really black):
And finally, in position. Personally I think it looks pretty slick with the unique Infinity reference cone:
Still have to finish up some wiring, run REW and integrate it but I'm pleased with the looks so far. Have enough room on the other side of the TV stand, might just have to build another!
Once again, many thanks to all those that contribute their time and knowledge to help out us newbies!