Fonken-- my 4th build

[Jim Shearer]

OK, I guess it’s time for me to start reporting on my Fonken build. I work so slowly that I hesitate to say anything until I’ve made significant progress.

For the benefit of newbies or those who need a little encouragement to get started, I will pontificate at length on some details. If the experienced builders have suggestions for improvements, by all means, chime in. Just remember that this is an approach for one who doesn’t have a wood working shop & can’t afford one.

The Fonken is my fourth build. I had originally planned to get at least one more under my belt before starting in on the small (but somewhat fussy) project. Build number 3, a Triska sub, didn’t fill the slot I intended: the XO in the plate amp doesn’t cross as low as it says; as a result, it doesn’t blend well w/ my FE108eSigma Metronomes. Hopefully, it will match the more bass challenged Fonkens. (If not, then I’ll need a better plate amp.)

For those who haven’t tried building yet, let me set the stage w/ a few bits of wisdom that the old timers may forget to say (‘cause it’s second nature to them so they don’t think about it anymore.)

1) Trust NO ONE, not even yourself! Maybe the old timers don’t need this, but making full size drawings and triple checking every measurement reduces my error rate.

2) That sheet of plywood may be premium quality, but it isn’t square.

3) Plan the work, then work the plan. Once you start pouring glue, it’s too late to rethink what you’re doing.

4) In the end, the only way to be sure you never make a mistake is to do nothing! When you do mess up, chalk it up as a learning experience--however painful that may be.

I found that I can buy Baltic Birch ply at the Curtis Lumber. At Home Depot and Lowes they had no clue what I was talking about. At the time I was looking to buy materials for the Fonkens, I couldn’t find any good ply at either HD or L. What they did have was either too warped or too beaten up. So I went to Curtis. They don’t have BB in the store, but can get it from their warehouse.

The BB I got is flat & in good condition, but the edges tend to chip out or fray, no matter what I use to cut it. So after I get the Fonkens tuned to my satisfaction, I plan to take them apart again and veneer them in red oak--which will match the stands I built for them.

End Part 1.

[lineup]

and the obvious
question
is of course:

What is Fonken?
... at least a short description i need
if you do not mind, jim

regars
lineup - has not the faintest idea what is a fonken

[Jim Shearer]

Part 2:

Having planned the work, including full size drawings, it’s time to make saw dust!

My table saw is too small for me to cut a full sheet of ply, so I use a guide and circular saw to cut the 5x5 sheet into slightly over-width strips. Then get the fence set on the table saw and cut those strips to precise width. Don’t change the fence until all pieces of a given width are cut!

Now cut the strips into appropriate size making sure that you get them square. If you don’t have the benefit of a table saw or need to make odd shaped pieces (like for a Metronome) you can make one piece as close to perfect as you can, then use a router with pattern follower or flush trim bit to replicate it. And keep the flush trim bit handy for later! A router is great for cutting holes, but it’s the flush trim bit that makes it indispensable to me.

I apply finish to all surfaces, inside and out, with the exception of areas which will be glued. I was quite sure that wood glue doesn’t hold on finished surfaces, but I did try it just to be certain I wasn’t ‘missing out’ on sealing glued areas. Yes, I was able to break apart pieces finished with polyurethane and then glued with wood glue.

One reason I am so slow in assembling is that I am applying stain/finish to surfaces before gluing, so that excess glue will wipe off easily. Prior experience tells me that no matter how hard I try, if glue gets on a fresh wood surface, I can’t clean it off well enough to get it to stain properly.

End Part 2

[Jim Shearer]

lineup,

No problem! Should have thought of that!

Fonken is a Planet10-HiFi (Dave Dlugos) design using a Fostex FE127 driver. Check out at:
http://www.planet10-hifi.com/fonken.html

[Scottmoose]

If one types the word 'Fonken' into google, it's also the first thing to come up. Ah, the wonders of modern technology & search engines...

[Pano]

Originally posted by lineup
lineup - has not the faintest idea what is a fonken

Wow - and I thought everyone on this forum knew the Fonken......

Was just listening to a pair 15 minute ago.

[lineup]

Originally posted by panomaniac
Wow - and I thought everyone on this forum knew the Fonken......
Was just listening to a pair 15 minute ago.

just proves me is spending still too much time in Solid State
and far from enough at Full Range & Loudspeakers

But thanks, now I know one thing more:
Fonken is a Planet10-HiFi (Dave Dlugos) design using a Fostex FE127 driver. Check out at:
http://www.planet10-hifi.com/fonken.html

Looks like a nice speaker!

fonken, frugal-phile ... there is no end to Dave's
planet10 [trademarks(diy)]

[planet10]

Originally posted by Jim Shearer

2) That sheet of plywood may be premium quality, but it isn’t square.

And sometimes the sheet may not be the same thickness on one side as the other.

dave

[Jim Shearer]

Originally posted by planet10


And sometimes the sheet may not be the same thickness on one side as the other.

dave

I check the thickness of the ply, but it didn't occur to me that there might be significant variation within the sheet. One more thing to worry about!

[strider75]

Having gotten the cabinets glued up (but not finished) recently, it makes me feel better that someone with more experience called them fussy to build. Good tips, Jim. The only thing that I could add to these, if I may:

If you plan on finishing them after listening to them, make sure to give yourself a finite time frame. Mine have been done for about 2 weeks now, I keep finding reasons why I shouldn't take the drivers out and start sanding. These things sound damn good, they're getting addictive!