I am in the last few hours of finishing my Pi Theater 4 speakers. I have made all the cutouts on the baffle. However, the hole I made for the horn flare (Eminence H290) seems too big. I could have sworn I made the cuts according to Wayne's plan. But most likely it's my mistake. The mounting holes for the lens are only about 1/8" from the edge of the hole. I was planning to use t-nuts, but there is no room. I'm even afraid to use regular mounting screws because the holes would be so close to the cutout. Any suggestions? Thanks early.
You could cut some strips of wood 1/4 x 3/4 (for 3/4 baffle) glue them on to the edge of the hole with yellow glue and use 1" blue masking tape to clamp the 1/4" thick strips to the edge of the cut out. Make sure you tape them in place so the strips are in no way proud of the baffle on the front side. It would be a good idea to let this one sit overnight before continuing on.
Wayne Parham Messages: 18723 Registered: January 2001
Illuminati (33rd Degree)
You've described a common issue. I hate how thin the lip is on that tweeter horn. The solution I've found is to run the mounting screws at an angle so they bite into more wood.
You could also use an adhesive, a "removable" one, like a siliconized latex. Lay the box on its back, run a bead, and drop the horn into the hole. Next morning you're good to go.
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