Wayne Parham Messages: 18789 Registered: January 2001
Illuminati (33rd Degree)
I like to cut the port holes on the baffle so the port tube fits snugly in them. Cut the port to the proper lenth with a table saw and apply a thin film of white glue on the edge to protect it. Put white glue on the baffle edge where the port goes and press it in flush to the baffle, wiping off any excess glue.
I also like to paint the interior of the port. You can do that with an aerosol can before gluing it in or you can use a paintbrush after assembly. If you spray paint the inside of the port, protect the outside where the white glue will be using masking tape. The cardboard adheres best when it isn't covered with paint.
Wayne Parham Messages: 18789 Registered: January 2001
Illuminati (33rd Degree)
Answers by numbers:
1. Use #6 pan head screws to attach the drivers to the baffle. You can get them at any hardware store, like Lowes, Home Depot or Sutherlands and even some department stores like Target or Walmart. If you can't find them with a black finish, you can paint the heads black with enamel and a small paint brush, like what you might use to paint a model.
2. Cut a rectangular hole 2-1/8" x 2-7/8" for the connector panel. We put them on the center of the back panel, 3" from the bottom.
3. The port is 2-1/2" diameter. I remember including the tube you should use, so look for a cardboard tube in the box. It's about 9" long. Cut two 3-1/2" long tubes from this with a table saw and glue them onto the baffle.
Wayne Parham Messages: 18789 Registered: January 2001
Illuminati (33rd Degree)
I prefer the thick cardboard tube we use to PVC or even the plastic ones made to be used as speaker ports. The mailer tube we use is very thick, strong enough you could use it as a baseball bat. It's made of the same "stuff" as the cabinet, being a paper product which is essentially a derivative of wood pulp. And it is well damped, making no sound of its own. The only thing a plastic tube has to offer is they are sometimes radiused, but the port airspeed in not a problem in any models of my speakers, so there's no benefit to be gained by radiusing the ports. For all these reasons, I have always preferred cardboard ports over plastic. Just paint the tube and seal the ends with glue as I described earlier in this thread.
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