Crossover Assembly Services & Custom Crossover Boards for DIYSG Kits - AVS Forum | Home Theater Discussions And Reviews
Forum Jump: 
 64Likes
 
Thread Tools
post #1 of 164 Old 05-17-2015, 09:41 AM - Thread Starter
AVS Forum Special Member
 
mtg90's Avatar
 
Join Date: Aug 2011
Location: Millbrook, IL
Posts: 1,936
Mentioned: 574 Post(s)
Tagged: 0 Thread(s)
Quoted: 760 Post(s)
Liked: 1577
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:




When assembled:






Last edited by mtg90; 04-25-2016 at 09:46 PM. Reason: 893/1099 board price increase effective 4-25-2016
mtg90 is offline  
Sponsored Links
Advertisement
 
post #2 of 164 Old 05-17-2015, 09:44 AM - Thread Starter
AVS Forum Special Member
 
mtg90's Avatar
 
Join Date: Aug 2011
Location: Millbrook, IL
Posts: 1,936
Mentioned: 574 Post(s)
Tagged: 0 Thread(s)
Quoted: 760 Post(s)
Liked: 1577
Photos of Fusion-15 crossover board:





Assembled:





Fusion-10:




893:


LTD02, W00lly, luisev and 2 others like this.

Last edited by mtg90; 11-21-2015 at 10:40 AM. Reason: Updates
mtg90 is offline  
post #3 of 164 Old 05-17-2015, 09:45 AM - Thread Starter
AVS Forum Special Member
 
mtg90's Avatar
 
Join Date: Aug 2011
Location: Millbrook, IL
Posts: 1,936
Mentioned: 574 Post(s)
Tagged: 0 Thread(s)
Quoted: 760 Post(s)
Liked: 1577
reserved for future info
mtg90 is offline  
Sponsored Links
Advertisement
 
post #4 of 164 Old 05-17-2015, 04:24 PM
Member
 
SilverSPL's Avatar
 
Join Date: Dec 2008
Location: Pennsylvania
Posts: 20
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 15 Post(s)
Liked: 3
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

Matt

Last edited by SilverSPL; 05-17-2015 at 04:31 PM.
SilverSPL is offline  
post #5 of 164 Old 05-17-2015, 06:12 PM
Member
 
ocpmach's Avatar
 
Join Date: Feb 2008
Location: Virginia
Posts: 57
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 14 Post(s)
Liked: 20
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.
ocpmach is offline  
post #6 of 164 Old 05-17-2015, 09:53 PM - Thread Starter
AVS Forum Special Member
 
mtg90's Avatar
 
Join Date: Aug 2011
Location: Millbrook, IL
Posts: 1,936
Mentioned: 574 Post(s)
Tagged: 0 Thread(s)
Quoted: 760 Post(s)
Liked: 1577
Quote:
Originally Posted by SilverSPL View Post
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.
mtg90 is offline  
post #7 of 164 Old 05-18-2015, 05:30 PM
Senior Member
 
Join Date: Feb 2015
Location: Clemson, SC
Posts: 321
Mentioned: 4 Post(s)
Tagged: 0 Thread(s)
Quoted: 142 Post(s)
Liked: 120
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
dorri732 is offline  
post #8 of 164 Old 05-19-2015, 09:59 AM
AVS Forum Special Member
 
wormraper's Avatar
 
Join Date: Jun 2006
Location: Tucson Arizona
Posts: 4,913
Mentioned: 6 Post(s)
Tagged: 0 Thread(s)
Quoted: 379 Post(s)
Liked: 232
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
wormraper is online now  
post #9 of 164 Old 05-22-2015, 12:41 PM
Senior Member
 
fabulousfrankie's Avatar
 
Join Date: May 2002
Location: Bristow, VA
Posts: 397
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 15 Post(s)
Liked: 16
Just in time!

Please tell me how do I order three Elusive 1099 boards?
fabulousfrankie is offline  
post #10 of 164 Old 05-27-2015, 03:17 AM
Member
 
SilverSPL's Avatar
 
Join Date: Dec 2008
Location: Pennsylvania
Posts: 20
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 15 Post(s)
Liked: 3
I just got my three 1099 crossover boards. They look great!

Matt
SilverSPL is offline  
post #11 of 164 Old 05-28-2015, 06:22 PM
AVS Forum Special Member
 
eng-399's Avatar
 
Join Date: Sep 2013
Location: Plainfield IL.
Posts: 5,494
Mentioned: 523 Post(s)
Tagged: 0 Thread(s)
Quoted: 2409 Post(s)
Liked: 4958
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!!
eng-399 is online now  
post #12 of 164 Old 05-28-2015, 06:47 PM
Member
 
dcgold2000's Avatar
 
Join Date: Aug 2011
Posts: 42
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 9 Post(s)
Liked: 13
Nice work. What process do you use to mill the boards? Thats obviously not freehand.
dcgold2000 is offline  
post #13 of 164 Old 05-30-2015, 04:29 PM - Thread Starter
AVS Forum Special Member
 
mtg90's Avatar
 
Join Date: Aug 2011
Location: Millbrook, IL
Posts: 1,936
Mentioned: 574 Post(s)
Tagged: 0 Thread(s)
Quoted: 760 Post(s)
Liked: 1577
Holes drilled with template on drill press. Copper milled using a shapeoko 2 desktop cnc.

mtg90 is offline  
post #14 of 164 Old 05-30-2015, 05:33 PM
Member
 
dcgold2000's Avatar
 
Join Date: Aug 2011
Posts: 42
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 9 Post(s)
Liked: 13
Quote:
Originally Posted by mtg90 View Post
Holes drilled with template on drill press. Copper milled using a shapeoko 2 desktop cnc.

https://m.youtube.com/watch?v=0so6Kf6yIPc
Way cool.
dcgold2000 is offline  
post #15 of 164 Old 05-31-2015, 10:45 AM
Member
 
Join Date: Aug 2014
Location: Hooper, Utah
Posts: 156
Mentioned: 6 Post(s)
Tagged: 0 Thread(s)
Quoted: 85 Post(s)
Liked: 73
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.
Aerumas is offline  
post #16 of 164 Old 06-01-2015, 07:17 PM
Member
 
Uncle Q's Avatar
 
Join Date: Nov 2013
Location: piedmont, NC
Posts: 64
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 30 Post(s)
Liked: 32
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 is offline  
post #17 of 164 Old 06-01-2015, 07:42 PM
Member
 
Uncle Q's Avatar
 
Join Date: Nov 2013
Location: piedmont, NC
Posts: 64
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 30 Post(s)
Liked: 32
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.
soto hd, rhaas12321 and lloydrmc like this.
Uncle Q is offline  
post #18 of 164 Old 06-01-2015, 08:01 PM
Member
 
dcgold2000's Avatar
 
Join Date: Aug 2011
Posts: 42
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 9 Post(s)
Liked: 13
Quote:
Originally Posted by Uncle Q View Post
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.
dcgold2000 is offline  
post #19 of 164 Old 06-02-2015, 11:51 AM
Member
 
Join Date: Aug 2014
Location: Hooper, Utah
Posts: 156
Mentioned: 6 Post(s)
Tagged: 0 Thread(s)
Quoted: 85 Post(s)
Liked: 73
Quote:
Originally Posted by Uncle Q View Post
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
lloydrmc likes this.
Aerumas is offline  
post #20 of 164 Old 06-04-2015, 02:49 PM
Member
 
sampsdds's Avatar
 
Join Date: Apr 2014
Posts: 35
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 6 Post(s)
Liked: 16
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, 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
Thanks in advance!
sampsdds is offline  
post #21 of 164 Old 06-04-2015, 07:13 PM
AVS Forum Special Member
 
W00lly's Avatar
 
Join Date: Jan 2007
Location: NEBRASKA
Posts: 2,110
Mentioned: 16 Post(s)
Tagged: 0 Thread(s)
Quoted: 57 Post(s)
Liked: 74
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.

Scott

The CopperFields Cinema

          Current Photo's

W00lly is offline  
post #22 of 164 Old 06-04-2015, 07:33 PM - Thread Starter
AVS Forum Special Member
 
mtg90's Avatar
 
Join Date: Aug 2011
Location: Millbrook, IL
Posts: 1,936
Mentioned: 574 Post(s)
Tagged: 0 Thread(s)
Quoted: 760 Post(s)
Liked: 1577
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 is offline  
post #23 of 164 Old 06-04-2015, 07:47 PM - Thread Starter
AVS Forum Special Member
 
mtg90's Avatar
 
Join Date: Aug 2011
Location: Millbrook, IL
Posts: 1,936
Mentioned: 574 Post(s)
Tagged: 0 Thread(s)
Quoted: 760 Post(s)
Liked: 1577
Quote:
Originally Posted by W00lly View Post
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.
mtg90 is offline  
post #24 of 164 Old 06-05-2015, 07:47 AM
Member
 
sampsdds's Avatar
 
Join Date: Apr 2014
Posts: 35
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 6 Post(s)
Liked: 16
Got the Sentinels fired up they sound incredible! They pair nicely with the Volt 10s...Thanks for the great products Matt!
mtg90 likes this.
sampsdds is offline  
post #25 of 164 Old 06-06-2015, 08:32 PM
Newbie
 
obilix's Avatar
 
Join Date: Apr 2010
Location: SJC, CA
Posts: 8
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 4 Post(s)
Liked: 1
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.
obilix is offline  
post #26 of 164 Old 06-11-2015, 08:13 PM
Member
 
Uncle Q's Avatar
 
Join Date: Nov 2013
Location: piedmont, NC
Posts: 64
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 30 Post(s)
Liked: 32
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.
Attached Thumbnails
Click image for larger version

Name:	1099 pcb 2.jpg
Views:	971
Size:	116.7 KB
ID:	771153   Click image for larger version

Name:	1099 pcb 1.jpg
Views:	643
Size:	147.1 KB
ID:	771161   Click image for larger version

Name:	Cherry Switch.jpg
Views:	418
Size:	7.5 KB
ID:	771169  
Uncle Q is offline  
post #27 of 164 Old 06-15-2015, 10:27 AM
Newbie
 
Join Date: Jun 2015
Posts: 7
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 8 Post(s)
Liked: 0
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
billybr is offline  
post #28 of 164 Old 06-15-2015, 04:56 PM
Member
 
Uncle Q's Avatar
 
Join Date: Nov 2013
Location: piedmont, NC
Posts: 64
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 30 Post(s)
Liked: 32
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.
Uncle Q is offline  
post #29 of 164 Old 06-19-2015, 06:40 AM
Member
 
ocpmach's Avatar
 
Join Date: Feb 2008
Location: Virginia
Posts: 57
Mentioned: 2 Post(s)
Tagged: 0 Thread(s)
Quoted: 14 Post(s)
Liked: 20
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.
Attached Thumbnails
Click image for larger version

Name:	connections filled in.jpg
Views:	1405
Size:	300.2 KB
ID:	784658  
ocpmach is offline  
post #30 of 164 Old 06-20-2015, 03:23 PM
Member
 
Join Date: Mar 2015
Location: Cleveland
Posts: 39
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 14 Post(s)
Liked: 5
Pm'd!
VRausch is offline  
Sponsored Links
Advertisement
 
 

Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page


Forum Jump: 

Posting Rules  
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off