| Pi midhorn [message #61164] |
Mon, 12 October 2009 13:33  |
biglaz
Messages: 32
Registered: May 2009
Location: Kentucky
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Baron |
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Does anyone have any construction suggestions or tips on building the Pi midhorn.
Thanks in advance,
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| Re: Pi midhorn [message #61167 is a reply to message #61164] |
Mon, 12 October 2009 14:53  |
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Wayne Parham
Messages: 18682
Registered: January 2001
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Illuminati (33rd Degree) |
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"Measure twice, cut once." 
OK, sorry. I realize that's the generic advice anyone would give. Here are some of my suggestions, things I learned from building many versions of prototypes of this horn and others.
- Build a mock-up with cardboard. That will give you an idea of scale, fitment and a general feel for what you're building.
- Get some cheap wood stock to build a second mock-up. That will give you an idea how to cut and fit the parts. On this one, don't worry about angled cuts, make everything a butt joint.
- Cut the square hole in the throat plate with a router and template, not a jigsaw. You want that hole to be perfectly square. The corners can be slightly rounded (as they will have to be if cutting with a router) but you defintely don't want a jagged edge or non-uniform square. It looks and sounds better if this is done right.
- When you get to making the final version, measure the angles carefully for fitting the flare pieces to the throat plate. That's probably the most important place to get an angled cut because it will make the horn look and sound better if there are no gaps there.
- You can make the horn slightly larger without penalty, but don't go smaller. It's been pushed as far as it will go to be physically small. When fitting the horn into a cabinet, you can use solid hardwood as sort of a front edge banding, and then either bevel to match the flare angle or radius the edge, or both.
- Other suggestions can be found in the post called "Finishing Details".
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