| Re: 4 Pi Build in San Luis Obispo - Progress [message #95582 is a reply to message #93009] |
Tue, 03 May 2022 12:08   |
alexg
Messages: 17
Registered: June 2019
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Chancellor |
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Finally starting to make some progress...... I was hoping to post as I go but I tend to work in fits and spurts when doing these kinds of projects and although I found time to work on the speakers I fell behind on my posts and updates.
In order to recess the wave guides, I ended up using the same template strategy that "Roger S" used. Thanks "Roger S!" At first I tried to use my jig to cut the shape of the wave guide directly into the baffle but really struggled to get the corners right. The jig was great for cutting the general shape of the wave guide but didn't allow me to effectively address the rounded corners. So, I ended up making the template per Roger S using my jig and router and then routed the corners by hand. It took me a several tries to get it right but after a few attempts I finally got one that I was happy with. From there I used the template to cut the baffle. Worked like a charm.
For the woofers, I beefed up the back side of the baffle with an additional piece of wood per Wayne's recommendation in order to give them a little more "meat" to attach to. Using my jasper circle jig I cut a round disc approximately 16.25" in diameter using some ¾" cabinet grade plywood that I had lying around and glued it to the back of the baffle. I then cut the recess and hole for the woofer.
From there I attached the baffles and vents using clamps and kettle bells.
For the most part I am pleased with my results thus far however I would like to point out a few issues.
#1 - Even though I had the local lumber yard cut my sheet of MDF to spec, after gluing up the box and then attaching the baffle my speaker was not perfectly square with some parts slightly hanging out over other parts. I ended up using a trim router to clean things up.
#2 - I pre-cut the hole for my vent with the intention of using a trim router to clean things up and make the opening flush and square however I got little too aggressive with the jig saw and over cut the opening in a few spots and then allowed the trim router to get away from me a few times so I now have to go back and fix the problem areas with some kind of wood filler. You can see it in the photo below and in some of the other photos in this post.
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Attachment: Inside and Front.jpg
(Size: 2.07MB, Downloaded 728 times)
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Attachment: #3 - Jig #5.jpg
(Size: 2.62MB, Downloaded 705 times)
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Attachment: Recessed baffle after jig saw.jpg
(Size: 3.26MB, Downloaded 686 times)
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Attachment: Baffle with round disc JBL BAcker.jpg
(Size: 2.37MB, Downloaded 573 times)
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Attachment: Router cutting JBL hole.jpg
(Size: 3.94MB, Downloaded 180 times)
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Attachment: Woofer Ring Back.jpg
(Size: 4.19MB, Downloaded 714 times)
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Attachment: Router cutting woofer hole.jpg
(Size: 4.45MB, Downloaded 694 times)
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Attachment: Baffle clamps.jpg
(Size: 2.13MB, Downloaded 679 times)
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Attachment: Kettle Bell Vent.jpg
(Size: 2.01MB, Downloaded 675 times)
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Attachment: Vent Issues.jpg
(Size: 2.02MB, Downloaded 695 times)
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