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-   -   Crossover Assembly Services & Custom Crossover Boards for DIYSG Kits (https://www.avsforum.com/forum/401-diy-sound-group-loudspeakers-subwoofers/2003178-crossover-assembly-services-custom-crossover-boards-diysg-kits.html)

mtg90 05-17-2015 09:41 AM

Crossover Assembly Services & Custom Crossover Boards for DIYSG Kits
 
As many of you are likely aware I am sort of the unofficial crossover assembly guy for DIYSG kits, this includes most of the assembled crossovers ordered with kits. I believe now is the time to start an official thread for this so the info can be posted in one place and hopefully reduce the number of emails Erich gets asking if there is a way to have their crossovers assembled.

Currently this works by contacting me, I will get you current price info and provide you with my mailing address so if you decide to have your crossover assembled you can send them here I will get started. Usual turn around is within two weeks from the time I receive the parts to when they are ready to ship back to you. Additional time may be required if the crossover is one I have yet to assemble requiring initial layout and design time.

Custom Crossover Boards
Something new I have been working on is to offer custom crossover boards for some of the more popular kits that don't have PCB's designed and built for them yet. These boards much like a PCB are drop parts in, glue and solder. The only differences being that I mill these myself from copper clad boards so the backside does not have traces but rather separations in the copper to divide the connections and there is no silkscreen print on the front so you must use a photo reference to place the components on the board. The benefit being you no longer have to worry about how to wire the crossover, just match the layout in the photo, glue parts down (I use hot glue) and solder! Ideal if you would still like to assemble the crossover but are worried about connecting everything correctly.

Boards I have designed and available (note just started on these more will be added as time goes on).
Elusive 1099 ($18)
Fusion-15 ($15)
893 ($18)
Fusion-10 ($13)
88-special ($13) - I don't have nice photos of the finished assembled boards yet.

Price is per board with the input/output terminals (which accept up to 12awg wire) and shipping included.

Smaller boards that do not use terminals (direct solder input output wires),
Fusion-8 tower / Cinema-8 ()
Fusion-8 Center ()
Overnight Sensations ()

Feel free to PM me for inquiries about purchasing boards or having your crossovers assembled.

Here are some pictures of the 1099 board:
https://lh4.googleusercontent.com/-R...2H_0705-sm.jpg

https://lh4.googleusercontent.com/-b...2H_0710-sm.jpg

When assembled:
https://lh4.googleusercontent.com/-m...2H_0702-sm.jpg


https://lh4.googleusercontent.com/-e...2H_0704-sm.jpg

https://lh6.googleusercontent.com/-D...2H_0701-sm.jpg

mtg90 05-17-2015 09:44 AM


mtg90 05-17-2015 09:45 AM

reserved for future info

SilverSPL 05-17-2015 04:24 PM

Well done Sir, I love it!

What kind of black adhesive did you use to bond the parts to the board?

I'll purchase 3 for the 1099

ocpmach 05-17-2015 06:12 PM

Thanks for your post, i am noob to the DIY world and about to order 2 x 1099's kits, was wondering how many XO PCB's do i need and how do i go about ordering and making payment?

You can PM me if you prefer ( I cannot PM as my post count is < 15).


Thanks.

mtg90 05-17-2015 09:53 PM

Quote:

Originally Posted by SilverSPL (Post 34293218)
Well done Sir, I love it!

What kind of black adhesive did you use to bond the parts to the board?

I'll purchase 3 for the 1099

Thank you.

It is just black colored hot glue. Many other adhesives can be used for attaching the parts to the board but hot glue is my adhesive of choice for being quick and odorless.

dorri732 05-18-2015 05:30 PM

Hi Mtg90,

I recommend you talk with Erich about listing the assembled crossovers as "in stock" on the DIYSoundGroup website. Many people will not know to check here for crossover assembly. Additionally, you might want to post on the forum there. I know it doesn't get the traffic that AVS does, but again, some might not know that we're here.

Cheers,
Dorri

wormraper 05-19-2015 09:59 AM

I will definitely hit you up if I get the Elusive 1099's this year... the crossover is the only thing that makes me want to get the Fusion 10 Max's

fabulousfrankie 05-22-2015 12:41 PM

Just in time!

Please tell me how do I order three Elusive 1099 boards?

SilverSPL 05-27-2015 03:17 AM

I just got my three 1099 crossover boards. They look great!

eng-399 05-28-2015 06:22 PM

I can't wait to hear those 1099's at the gtg. I would like to have those in my room down the road and will defiantly have Matt build those boards for me when I buy them. They look very nice in the pictures! Great work!!

dcgold2000 05-28-2015 06:47 PM

Nice work. What process do you use to mill the boards? Thats obviously not freehand.

mtg90 05-30-2015 04:29 PM

Holes drilled with template on drill press. Copper milled using a shapeoko 2 desktop cnc.


dcgold2000 05-30-2015 05:33 PM

Quote:

Originally Posted by mtg90 (Post 34629841)
Holes drilled with template on drill press. Copper milled using a shapeoko 2 desktop cnc.

https://m.youtube.com/watch?v=0so6Kf6yIPc

Way cool.

Aerumas 05-31-2015 10:45 AM

I placed a preorder for 3 1099s a few weeks ago, so I'd like to order 3 of these from you for my setup. Feel free to PM me the info for payment.

Uncle Q 06-01-2015 07:17 PM

As someone who etched his last PC board decades ago, the CNC board seems like magic! And for crossover use, it's genius since the max-width "traces" permit greater current flow and promote adequate damping of the drivers. Although those benefits might be slightly more imagined than real, the benefit of short run construction ease can't be denied. Great job!

I would like to order three boards right away, but, like Aerumas, don't have enough posts to PM you. If you would be so kind as to PM me, I will order today.

PS looked in the classified section, but didn't see you there.

Uncle Q 06-01-2015 07:42 PM

Had to laugh when I saw that my post count was 14. I truly thought it was in the single digits.

Lest the moderators think this to be a frivilous post to engorge my count to PM level, let me say that I consider the moderators to be gentlemen of the most outstanding character and whose collective senses of humor to be among the most refined upon the planet. Plus, good looking, etc., etc.

dcgold2000 06-01-2015 08:01 PM

Quote:

Originally Posted by Uncle Q (Post 34686305)
Had to laugh when I saw that my post count was 14. I truly thought it was in the single digits.

Lest the moderators think this to be a frivilous post to engorge my count to PM level, let me say that I consider the moderators to be gentlemen of the most outstanding character and whose collective senses of humor to be among the most refined upon the planet. Plus, good looking, etc., etc.

Don't forget they are really fine dancers as well.

Aerumas 06-02-2015 11:51 AM

Quote:

Originally Posted by Uncle Q (Post 34686305)
Had to laugh when I saw that my post count was 14. I truly thought it was in the single digits.

Lest the moderators think this to be a frivilous post to engorge my count to PM level, let me say that I consider the moderators to be gentlemen of the most outstanding character and whose collective senses of humor to be among the most refined upon the planet. Plus, good looking, etc., etc.

Ditto ;)

sampsdds 06-04-2015 02:49 PM

Matt, I am VERY impressed by the Fusion 15 crossover quality and the speed with which they were completed and returned! These really look outstanding and the care put into packaging is evident.

I am equally intimidated by them:D, being the complete noob that I am! When I connect these I assume that the terminal block labeled [o o o o] will have all of the negative leads from their respective input/output.
-IN HF LF

Terminal block [o o] will have a the positive lead from the CD...
+HF

Terminal block [o o] will have the positive lead from the woofer...
+LF

Terminal block [o o] will have the positive lead from the input...
+IN


Are my assumptions at least on the right track?
Very sorry for the lame diagram and the beginner question:o
Thanks in advance!

W00lly 06-04-2015 07:13 PM

Matt
Since your input/output terminals accept up to 12awg wire on your 1099 boards what do suggest as a happy medium 16awg or 14awg zip wire or go 12awg because I can.

mtg90 06-04-2015 07:33 PM

Kyle, thanks and yes your are correct with your assumption of the wiring.

The terminals I use have connection points but you can use either for what is marked. Same goes for the common negative connection which is just two of the terminals locked together, all 4 are the same connection so you can wire the negative leads in any order on that set.

mtg90 06-04-2015 07:47 PM

Quote:

Originally Posted by W00lly (Post 34768641)
Matt
Since your input/output terminals accept up to 12awg wire on your 1099 boards what do suggest as a happy medium 16awg or 14awg zip wire or go 12awg because I can.

No reason to go with 12awg for these short runs that is just going to make it harder to connect the drivers and get it into the terminals. 16 gauge is plenty and even 18 gauge would likely be just fine.

sampsdds 06-05-2015 07:47 AM

Got the Sentinels fired up they sound incredible! They pair nicely with the Volt 10s...Thanks for the great products Matt!

obilix 06-06-2015 08:32 PM

If you guys are being blocked sending PMs and don't have the number of posts to do so, using tapa talk gets around that rule.

I thought I posted a reply to mtg90 last week on the board and it didn't go through.
Use tapa talk and boom! pm goes through.

Uncle Q 06-11-2015 08:13 PM

3 Attachment(s)
Matt...Thanks for the quick shipment of the three 1099 boards! They will add a professional touch to my 1099s-soon-to-be. You've done a terrific job on them. Anyone would be proud to incorporate these into their 1099 build.

I appreciate the photo included in your order confirmation PM. This isn't my first crossover build, but for anyone who is approaching crossover assembly for the first time, rest assured, you can't screw your project up if you go this route. (OK, anything's possible, but you'd have to try REALLY hard. And, BTW, soldering is way easy if that's holding you up.)

The packaging was Erich-Class as well.

No one really needs more pix of these, but they say if you don't show it you ain't done it...so here:

Now, that last picture of the Cherry RRA22H3FBRNN switch doesn't exactly belong in this post, but I came to a decision to order it while assembling the crossover. Why? Because of that optional 10-ohm resistor that Erich kindly included in the 1099 crossover parts kit. You stuff the board, and there it sits, a "leftover," suggesting, nagging, really, that you should do something with it. It's the CD shunt resistor that Matt offered as a way to gently drop the CD level a touch for anyone who found the overall tonal balance to be a bit bright. Some have said it is.

Since I haven't heard a 1099 (What? I spent WHAT? and haven't heard them? Thanks, Fatshaft et al), I can't have an opinion, but I do want the option. Perhaps the center will need all the electrons it can eat for extra clarity while the L/R could use the attenuation. Perhaps with the speakers in this location yes, over there on that wall, no. Perhaps I'm just in the mood for a change? Well, for $8.68 including shipping for three of these, I don't have to wonder. It's a simple SPST switch which will move the shunt resistor in and out of the CD circuit thereby siphoning off a bit of the current which would otherwise flow through the CD and out through the SEOS. I picked it for its easy to install round shape...~3/4" dia. bit should do it. It will go right beside the Speakon socket.

If you want to go this route, just run an extra wire from the unused second HI screw terminal to the resistor, then to the switch, and then back to the multipoint grounding block on the pcb.

I considered Dremeling an "island" in the HF pad and squeezing the resistor onto the board between the 0.5 mh inductor and the 25 uf cap, and then using one of the two HF green terminal block connection points to route to the switch. But, that seemed unnecessary. Just a dab of hot glue on the inside of the back panel of the enclosure right near the switch will be all that's necessary to hold the resistor in place.

billybr 06-15-2015 10:27 AM

I am preordered two of the 1099s today, PM with pricing and instructions on how to get the boards from you. I've already spoke with Erich

Uncle Q 06-15-2015 04:56 PM

Scott, Tracking says the switches will be delivered tomorrow. But, I just began making sawdust Saturday. Things move at a snail's pace here. So, I will surely post pics, but may not be right away. Your build is phenomenal! And inspiring. Checked post #1 , then couldn't resist a quick skim through.

My "screening room" (gives me lots more latitude than "home theater," eh?) is somewhere between conception and embryo, but way more modest than yours. However, when the lights dim & the sprockets churn........ we'll be listening through the same speakers! YeeHaa! Thanks, Tux & Erich & many, many others.

PS I forgot to mention that the $1.23 switches were ordered from Mouser with "econ shipping"...read UPS/USPS combo. But, most any SPST switch should work...could probably have just gone to the Shack.

ocpmach 06-19-2015 06:40 AM

1 Attachment(s)
Thanks to Matt for coming up with this PCB design, it makes XO assembly so much easier for noobs like me, i am attaching a picture(provided by Matt) which shows how PCB terminals connect to various speaker components, hopefully this helps other members.

VRausch 06-20-2015 03:23 PM

Pm'd!


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