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Discussion Starter #1
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.
 

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Hey, those monkey coffins look familiar! Coming together pretty quick after ripping stuff on Friday, especially given how big of a dent we put in that bottle of Crown!


You gonna paint the inside of the ports black?


Once those 2pi are done, I'll have to bring my Jack of All Trades 8 over to compare output and response.
 

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Nice. I built a pair of 1pi's last year for surrounds. I am sure you're going to like your 2pi's.


What exactly did you get at Staples to use for ports? I know Wayne advocates the use of paper ports, instead of plastic.


I am not quite sure what the reasoning is behind that, but hey the man uses so I guess it must work.


I am going to need ports material for an SEOS build, and like to take a look at this Staples stuff.


And yeah, great clamps.
 

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Quote:
Originally Posted by nube  /t/1475658/2-pi-surround-speaker-project#post_23395260


It was paper mailer tube from Staples, cut to size. The exact tube with bar code and UPC code is in this pic:



Thanks. I'll have to make a quick trip to Staples to pick up some of these tubes.
 

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Discussion Starter #16
Wednesday Project:

I ran roundover bit around the front baffles. I didn't take any pictures of the router work - too much dust.


When I got done with the baffles I just had to do something to dress up the Easy Button Port Tubes. I raised the 3/4" roundover bit so only about 1/4" was below the router baseplate and ran it around the inside of the port tube.


Before:



Progress shot:



After:



A little touch up with sandpaper and the Duratex treatment will hide the truth from all but the most experienced DIY speaker builder.
 

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Discussion Starter #18

Quote:
Originally Posted by smokarz  /t/1475658/2-pi-surround-speaker-project#post_23394868


Nice. I built a pair of 1pi's last year for surrounds. I am sure you're going to like your 2pi's.

I read through your pi build a couple of times. Good stuff!


I saw Star Trek Into Darkness in a commercial theater a couple of weeks ago. I realized my mishmash of surrounds really suck, so it got me off my butt to make dust. Looking forward to putting them through their paces!
 

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Discussion Starter #19
Filling and sanding done.



First coat of Duratex goes down.



The crappy veneer has bubbled up in a couple of places. Need to sand down to solid wood and recoat those areas. Then I'll do the final rolled finish. The air is so dry here that the Duratex is dry to the touch within a few minutes. Might make it tough to roll out a smooth finish. Relative humidity is 37% now at 7:30 AM and headed down into single digits.
 
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