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This thread will detail the build of my L/C/R 88 Specials and Surround/Rear Surround Volt 10's. This thread will be wordy and picture-intensive. You've been warned.
I love build threads. The pics, warts and all, and the journey of the build is what it's all about for me. If you're reading this, you already understand the draw of DIY; value for the money, better sound and capability than commercial offerings for 1/2 the price and the pride of saying "Those? I built those. YES, I built those!"
A little background on me and why I am building these. I've been a HT nut since the days of Dolby Pro Logic and whatever puny Kenwood speakers I bought from Crutchfield and a music nut way before that. For HT, over the years I progressed through various levels of off-the-shelf mains/surrounds/subs. My current setup...well, it's in the closet at the moment, but when it was setup is Axiom M22s L/R, VP150 Center & QS8s for L/R surround, powered by a Denon 3803. Sub is a SVS PB2-plus. It's been a great setup, but you know how it goes...bigger, better, faster, more! I decided I wanted to try something new...something potentially better. Lurked a bunch of DIYSG threads, asked some questions, weighed my options and here I am.
Now to the DIY part. "Back in the day" I built tens of car audio sub cabs for myself and friends. They weren't all pretty but they worked just fine. 5CF in a Honda to 12CF in a full sized fan. Sealed, ported with PVC pipe, slot ported, band pass; been there done that. Me and MDF go way back *cough-cough-damn MDF dust!* I've also built DIY PA cabs before as well. I built/own 4 BFM OTop12s and 4 T48s and have been very happy with them. So I am no stranger to DIY.
I have the tools and skills to build my own cabs, but this time around I gave myself a break and bought full kits. I'm a "looks good to the untrained eye" woodworker so anything CNC cut puts me to shame. Especially a CNC cut baffle for an 88 Special. I could do it, but it wouldn't be pretty. Also, a big part of the decision to do away with most of the "Y" in "DIY" for this build was the fact that my garage is now essentially 20% woodshop and 80% storage depot. I'm out of room...no place to roll out the table saw/outfeed table, etc. Which is part of the reason we're moving to a bigger house, which means I get a dedicated HT room, which is why I'm building these speakers. I DID mention this thread would be wordy. :angel:
Did I mention this would be a wordy thread? If you haven't already replied "TLDR", then you're in the right place, my friend.
Still with me? Great.
I took delivery today of 5 large boxes. None were particularly heavy but together weighed 259 pounds. Here, for your viewing pleasure, is 259 pounds of awesome.

And now to give full credit where credit is due. I had read about Erich's skills with packing these kits, but I'm pretty difficult to impress. I sell lots of stuff I no longer need online, so I ship a fair amount of oddly-shaped items myself. But I was not prepared for the Wizard Level 50, Dragonplate Armor, bomb-proof packing I experienced today. I'm sure it has happened that one of Erich's kits arrives damaged, but I'd bet good money it fell off the FedEx truck at 60mph, got run over by an Abrahams Tank and then trampled by 50 kindergarten-aged children. I've actually never seen something packed this well.
This box contains a single 88 Special kit. (baffle/drivers/horn/xover+the flat pack)

Open it and you see this. Tons of...cubes. QBERT!!! Remember the video game QBert? No Styrofoam peanuts here! We gots us some cubes!

Ho-lee-crap, this thing is packed well...let's clear this crap away....and we get...

A package within a package...WTH? Dig it out and we have... a mini-pallet!


Turns out Erich ships the kits "mini-palletized." It's a brilliant idea, really. Instead of a hundred little pieces floating around in a sea of peanuts..er...QBerts...you have one solid "package". And trust me, that little pallet is well-isolated from the outside world. Not a single dent in any of MDF panels, nor a squish of any of the cardboard boxes that hold the drivers/xover parts.
OK, wow, color me impressed!
So let's take it apart. Oooooooh. Aaaaaaah. This is an 88 Special, then. I so COULD NOT DO THAT for the baffle.
My router-foo is weaksauce compared to the CNC-FU-OF-DEATH.


I have never seen a 15" horn before. It's big. Like really big. Here it is next to my ordinary Dewalt cordless drill/driver.

Like I said, that is one big horn.
All right. Onto the smaller boxes.
The Volt 10s were packed exactly like the 88's; bomb-proof. Here's angled Volt-10:

Note the matching angle of the top/bottom panels so that the baffle sits flush. A nice touch.

And lest you doubt the packing-mastery for these kits; here is a shot of my previously-empty trash can full of JUST kraft paper, Styrofoam blocks, cardboard angle pieces and filler strips.

What you don't see is the 40-gallon trash bag full of the styro peanuts/QBerts. The packaging of these kits literally could not be better. Thank you, Erich.
Tomorrow I will begin the actual build. I build cabs with PL Premium, brad nails and clamps. They will be finished in Duratex. Still undecided if I will round off the corners on all/some/none of the boxes. The room they are going in will be very dark, so probably not. But we'll see.
Thanks for reading! Much more to follow.
I love build threads. The pics, warts and all, and the journey of the build is what it's all about for me. If you're reading this, you already understand the draw of DIY; value for the money, better sound and capability than commercial offerings for 1/2 the price and the pride of saying "Those? I built those. YES, I built those!"
A little background on me and why I am building these. I've been a HT nut since the days of Dolby Pro Logic and whatever puny Kenwood speakers I bought from Crutchfield and a music nut way before that. For HT, over the years I progressed through various levels of off-the-shelf mains/surrounds/subs. My current setup...well, it's in the closet at the moment, but when it was setup is Axiom M22s L/R, VP150 Center & QS8s for L/R surround, powered by a Denon 3803. Sub is a SVS PB2-plus. It's been a great setup, but you know how it goes...bigger, better, faster, more! I decided I wanted to try something new...something potentially better. Lurked a bunch of DIYSG threads, asked some questions, weighed my options and here I am.
Now to the DIY part. "Back in the day" I built tens of car audio sub cabs for myself and friends. They weren't all pretty but they worked just fine. 5CF in a Honda to 12CF in a full sized fan. Sealed, ported with PVC pipe, slot ported, band pass; been there done that. Me and MDF go way back *cough-cough-damn MDF dust!* I've also built DIY PA cabs before as well. I built/own 4 BFM OTop12s and 4 T48s and have been very happy with them. So I am no stranger to DIY.
I have the tools and skills to build my own cabs, but this time around I gave myself a break and bought full kits. I'm a "looks good to the untrained eye" woodworker so anything CNC cut puts me to shame. Especially a CNC cut baffle for an 88 Special. I could do it, but it wouldn't be pretty. Also, a big part of the decision to do away with most of the "Y" in "DIY" for this build was the fact that my garage is now essentially 20% woodshop and 80% storage depot. I'm out of room...no place to roll out the table saw/outfeed table, etc. Which is part of the reason we're moving to a bigger house, which means I get a dedicated HT room, which is why I'm building these speakers. I DID mention this thread would be wordy. :angel:
Did I mention this would be a wordy thread? If you haven't already replied "TLDR", then you're in the right place, my friend.
Still with me? Great.
I took delivery today of 5 large boxes. None were particularly heavy but together weighed 259 pounds. Here, for your viewing pleasure, is 259 pounds of awesome.

And now to give full credit where credit is due. I had read about Erich's skills with packing these kits, but I'm pretty difficult to impress. I sell lots of stuff I no longer need online, so I ship a fair amount of oddly-shaped items myself. But I was not prepared for the Wizard Level 50, Dragonplate Armor, bomb-proof packing I experienced today. I'm sure it has happened that one of Erich's kits arrives damaged, but I'd bet good money it fell off the FedEx truck at 60mph, got run over by an Abrahams Tank and then trampled by 50 kindergarten-aged children. I've actually never seen something packed this well.
This box contains a single 88 Special kit. (baffle/drivers/horn/xover+the flat pack)

Open it and you see this. Tons of...cubes. QBERT!!! Remember the video game QBert? No Styrofoam peanuts here! We gots us some cubes!

Ho-lee-crap, this thing is packed well...let's clear this crap away....and we get...

A package within a package...WTH? Dig it out and we have... a mini-pallet!


Turns out Erich ships the kits "mini-palletized." It's a brilliant idea, really. Instead of a hundred little pieces floating around in a sea of peanuts..er...QBerts...you have one solid "package". And trust me, that little pallet is well-isolated from the outside world. Not a single dent in any of MDF panels, nor a squish of any of the cardboard boxes that hold the drivers/xover parts.
OK, wow, color me impressed!


I have never seen a 15" horn before. It's big. Like really big. Here it is next to my ordinary Dewalt cordless drill/driver.

Like I said, that is one big horn.
The Volt 10s were packed exactly like the 88's; bomb-proof. Here's angled Volt-10:

Note the matching angle of the top/bottom panels so that the baffle sits flush. A nice touch.

And lest you doubt the packing-mastery for these kits; here is a shot of my previously-empty trash can full of JUST kraft paper, Styrofoam blocks, cardboard angle pieces and filler strips.

What you don't see is the 40-gallon trash bag full of the styro peanuts/QBerts. The packaging of these kits literally could not be better. Thank you, Erich.
Tomorrow I will begin the actual build. I build cabs with PL Premium, brad nails and clamps. They will be finished in Duratex. Still undecided if I will round off the corners on all/some/none of the boxes. The room they are going in will be very dark, so probably not. But we'll see.
Thanks for reading! Much more to follow.