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Discussion Starter · #1 · (Edited)
I've been gathering up parts and supplies to build a pair of Wayne Parham's 7Pi corner horns and a 4Pi center channel for quite some time. I've finally cleared enough stuff off the "to do" list that I can get this project underway.

The speakers will be behind an AT screen and acoustically transparent screen wall, so I'm not getting fancy with the cabinets. I'm using decent quality BC plywood from the big orange box. I'll apply duratex for a quick and easy finish that looks decent. I do plan to take the time to make the mid horns nice looking since they're much more complicated to build than the bass bins. If I ever want to use the 7Pi corner horns out in plain sight I can always build nice looking bass bins.

I made good progress on the bass bins for all three speakers today. All the wood is cut and the sides and tops are glued together. I've also fabricated the ports, and installed the 4pi port into its cabinet.







Here's a closeup of a couple of the compression drivers and the crossover PC boards.





Box construction is straightforward - dado joints, cleaned up with a flush trim bit. The baffles will be glued in place. (sorry these got rotated when I was fixing the broken photobucket links)








I'll run a roundover bit over all the edges and slather duratex on for finish. I used the same method on my 2Pi surrounds.








I have not ordered crossover parts yet (except for the PC boards). I'll do that in the morning with my hot Costco Java.
 

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Great to see another Pi speaker build!!!!!!!! The 7 Pi's have always intrigued me and if I get an HT space in the future that has appropriate corners they are on the short list. Since I already have 4 Pi L/C/R would build a few more for center and surrounds.

What drivers are you going with for the build?
 

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I have the 7pi's with the same drivers and really like them. I use them almost daily. Wayne is great guy to work with too. Always very helpful.
 

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Very cool, I wonder why the pi kits aren't seen too often. They are very efficient correct?
They were more popular years ago. There are quite a few members around here with 3pi and 4pi systems. You don't hear much from them because they are all very happy with them. :)

With the explosion of equivalent kits from DIYSG, there has been little interest (around here) for Wayne's stuff.

My guess is that there is a lot more DIY involved with Wayne's products where the DIYSG is more turn-key AIY and more accessible to newbies. Not that there is anything wrong with that. Just a different crowd.
 

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Discussion Starter · #9 · (Edited)
I got a bit more done yesterday. Both rear baffles are glued in place and flush trimmed.








Regarding earlier comments about relative scarcity of Pi builds, I do think the task may be a bit intimidating to someone with less woodwork experience. Although Wayne's free plans have all the info needed for a successful build, they certainly aren't "how to" guides. You've got to figure out all the construction details for the cabinetry. Unless you purchase Wayne's kits, gathering the parts may be more than some want to tackle. I have spent a lot of time figuring out what components to order for the crossovers. I'm using the official PC boards, so that's a big help.

I'm looking forward to hearing these!
 

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Nice! So happy to see somebody building Wayne's 7pi system.

I use his midhorn kits in my custom LCR's. They are awesome and I know your 7pi's will be awesome as well.

Good luck!
How difficult are the mid horn kits to assemble? What driver are you using in yours? I have considered building a custom one off center channel using his mid horn with two 2226's below and a Seos-15 on an FL-450, never decided on the most optimal driver for the mid horn. I would probably end up building this thing if I could find someone to do the crossover. If I did build it, I would use an active crossover. Not for simplicity but rather having the built in ability to really dial it in tight, not have problems with sensitivity matching, and the ability to dsp.
 

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How difficult are the mid horn kits to assemble? What driver are you using in yours? I have considered building a custom one off center channel using his mid horn with two 2226's below and a Seos-15 on an FL-450, never decided on the most optimal driver for the mid horn. I would probably end up building this thing if I could find someone to do the crossover. If I did build it, I would use an active crossover. Not for simplicity but rather having the built in ability to really dial it in tight, not have problems with sensitivity matching, and the ability to dsp.
Pretty easy to assemble, actually. The driver is an Eminence Delta10 and is optimal for the midhorn. Wayne only suggests to use it or a very tough to source JBL 10" mid. I would not recommend using anything else unless you really want to experiment a lot.

Your system sounds like what I built with a different top end. I am full active with a DCX.
 

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Discussion Starter · #12 · (Edited)
He's Back....

I finally found some time to work on my Pi project. I started by adding bracing to the bass bins. I cut a bunch of oak remnants I had lying around into 3/4 x 1" sticks for the braces. I'm just winging it, with some guidance from Wayne's comments and using the experience I gained building subs and surrounds. On the left is the four center with the beginnings of bracing. On the right is the completed seven LR.





Here's a closeup of the seven.





And all three together.





I added sticks until the boxes passed the knuckle test. They're pretty solid.
 

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Discussion Starter · #13 · (Edited)
Onward to stuffing. These are R13 batts glued in with 3M number 77 spray adhesive. Not much to say other than "yuk". I'm glad I don't insulate houses for a living.






I had to deal with inspectors.






A mess of clamps and the baffles are glued on.





Titebond 2 is my glue of choice.







Here's another action shot. I've managed to latch onto some Breaking Bad memorabilia. Gustavo Fring lived a few blocks away. I often have lunch at Loyola's restaurant on Central, the place Mike used to frequent.


 

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Discussion Starter · #14 ·
Dry fit drivers into the four center.


Boxes are flush trimmed, edges rounded over, voids puttied, and 60 grit sanding complete...ready for my industrial grade finishing. I shot some black paint into the ports.


Closeup. These things are gonna be pretty rough since they'll live behind the screen wall.


Finished bass bins. Two coats of duratex works great. I used a 4" wide roller with 3/8" nap and got a pretty good finish.



Now on to building the seven pi mid horns. Hopefully I won't take five months to post another update!
 

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Looking good. bet those sound great when finished
 

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Love it. @eng-399 has a pair of 2pi surrounds.


Your boxes look great good job on them. I'm still liking my 2pi surrounds I have no complaints about them. I think you will really like your Setup when finished.
 

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Discussion Starter · #20 ·
Your boxes look great good job on them. I'm still liking my 2pi surrounds I have no complaints about them. I think you will really like your Setup when finished.
I built four 2π surrounds a couple of years ago. They're great and are what inspired me to build the π mains.
 
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