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Old 10th June 2018, 01:44 PM   #1621
Rullknufs is offline Rullknufs  Sweden
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Originally Posted by Fredrik93 View Post
I've googled some more and there seems to be a few sites which sell a lot of different types of plywood. They are just not regular stores so I guess I will have to do a custom order.
I have had the same problem. I ended up getting my birch ply from Halland Audio Design i Kungsbacka when I ordered a speaker kit from them. They had 18mm high quality birch ply available, but this was in 2012/2013 so things might have changed. Custom orders might be tricky, because last time I checked they wanted you to order at least like 10 or 20 boards and most only sell to companies, not home gamers like you and me. But hey, you could always ask Bauhaus, Byggmax, K-Rauta, Beijer, and the other stores if they could do a special order for you but I don't think it will be very cheap.
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Old 10th June 2018, 06:41 PM   #1622
Fredrik93 is offline Fredrik93  Sweden
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Thanks for all the answers!

Quote:
Looking pretty is a side-effect. The purpose is for audio quality.

Alternatively to the rebate, you could surface moun tthe driver, and then build-up the baffle around the driver with something easy to cut like cork. 8.5mm without the decorative bezel cover, 10mm with.
Okay, then I will try to make it work anyway. Maybe my neighbour can help out

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I must say that I made mine from MDF about 7 years ago and have never regretted it even though I had listened to some made from ply. But then perhaps I am not so fastidious as Dave and friends (sorry Dave:-)
Okay, good to know

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Frederik, if you are close to Malmo and Copenhagen you might able to pop across for the wood. Donít know what the Swedish wood prices are like but you can get good quality ply in e.g. XL here at quite reasonable prices. Alternatively you could ask your Home Depot if they can order some for you, as their suppliers might also stock some of the better stuff, the depot just doesnít have it in shop because few consumers buy it.
I unfortunately live in Stockholm. Would probably cost a lot to travel there just for some plywood... Will definitely ask the local shops if they can order in some for me if I can't get it from the specialised shops.

Quote:
I have had the same problem. I ended up getting my birch ply from Halland Audio Design i Kungsbacka when I ordered a speaker kit from them. They had 18mm high quality birch ply available, but this was in 2012/2013 so things might have changed. Custom orders might be tricky, because last time I checked they wanted you to order at least like 10 or 20 boards and most only sell to companies, not home gamers like you and me. But hey, you could always ask Bauhaus, Byggmax, K-Rauta, Beijer, and the other stores if they could do a special order for you but I don't think it will be very cheap.
Yeah I noticed that as well. I am looking at this site "calexicowood.se", haven't seen any text about not sending to individuals yet, but maybe that have such a rule anyway. I will send them a message tomorrow.
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Old 11th June 2018, 10:34 AM   #1623
twocents is offline twocents  South Africa
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Originally Posted by Fredrik93 View Post
Took me a while to decipher this since I haven't understood all the diy language, but I think I got it. I understand that the bezel is wanted/required on the inside. However, the driver cutout on the outside, is this required other than the fact that it looks better when the driver isn't protuding out? I have a feeling it will be difficult to do this cutout with the tools I have at hand.
Fredrik, just to help you visualize the terminology - see the attached photo. On the left you see the front of the baffle with a rebate - for the speaker driver to be mounted flush with the front of the baffle. On the right you see the back of the baffle with a chamfer - a 45 degree cutout at the back between the mounting bolts. Both are important for better sound.
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Old 11th June 2018, 02:03 PM   #1624
chrisb is offline chrisb
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Jerry - thanks for the picture - says it all

It should be noted that not all “full-range” drivers require the rebate - i.e. those with thinner / tapered flanges such as many of the Fostex, Mark Audio Pluvias and CHN70, and probably other.

However, with the very shallow cones and total mounting depth, I think all should have the chamfer / bevel to rear side of cut-out to avoid cavity resonance.
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Old 12th June 2018, 08:46 PM   #1625
Fredrik93 is offline Fredrik93  Sweden
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Quote:
Originally Posted by twocents View Post
Fredrik, just to help you visualize the terminology - see the attached photo. On the left you see the front of the baffle with a rebate - for the speaker driver to be mounted flush with the front of the baffle. On the right you see the back of the baffle with a chamfer - a 45 degree cutout at the back between the mounting bolts. Both are important for better sound.
Thanks, these kind of pictures help
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Old 15th July 2018, 01:10 PM   #1626
Fredrik93 is offline Fredrik93  Sweden
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Hello again!

I've decided against going with plywood for a few reasons. Mainly because it was so hard to get in good enough quality. I also figured that MDF will be easier for me to work with, and since I've never built anything like this before I think I'll make it as easy as possible for me. I don't think I would notice the difference unless I did an A + B test either. Furthermore, if I do feel like the sound isn't good enough, I can just build a new pair!

However, I noticed another problem. My initial plan was to create it in 15mm with the 18mm baffle. There doesn't seem to be a lot of 15mm MDF around here unfortunately... So my plan now is to use the 16mm plan and modify it to use a 18mm baffle (since I had the Alpair which required 18mm baffle). So extending the side parts by 2mm so that they cover the 18mm baffle piece. So that the enterior volume will remain exactly the same, but the baffle will stick out another 2mm.

What do you think?
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Old 15th July 2018, 04:44 PM   #1627
mikejennens is offline mikejennens  United States
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Originally Posted by Fredrik93 View Post
Hello again!

I've decided against going with plywood for a few reasons. Mainly because it was so hard to get in good enough quality. I also figured that MDF will be easier for me to work with, and since I've never built anything like this before I think I'll make it as easy as possible for me. I don't think I would notice the difference unless I did an A + B test either. Furthermore, if I do feel like the sound isn't good enough, I can just build a new pair!

However, I noticed another problem. My initial plan was to create it in 15mm with the 18mm baffle. There doesn't seem to be a lot of 15mm MDF around here unfortunately... So my plan now is to use the 16mm plan and modify it to use a 18mm baffle (since I had the Alpair which required 18mm baffle). So extending the side parts by 2mm so that they cover the 18mm baffle piece. So that the enterior volume will remain exactly the same, but the baffle will stick out another 2mm.

What do you think?
If there is only a 2mm difference in the baffle, I can't imagine that would make any audible difference anywhere within the range of human hearing. Some speaker designers go so far as to say anything within 10% of the original design is acceptable. I don't believe I would go the 10% route on the Frugal-horns, but I would be fine with a baffle 2mm thicker than the original design if that was my only good option.
Plus, if that is the only option, they will sound far better than if you abandoned the project entirely.
Mike
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Old 15th July 2018, 05:19 PM   #1628
Scottmoose is offline Scottmoose  United Kingdom
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It'll be fine. Alternatively, just use 18mm throughout. A bit heavy, but stiffness will improve & with MDF you need all you can get so that would be my preferred option.
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Old 16th July 2018, 08:33 AM   #1629
jemraid is offline jemraid  United Kingdom
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Hello Fredrik,

I made mine from 18.0 mm MDF, with the usual precautions, face mask, do the cutting outdoors.
I also had only very basic tools and had to resort to all sorts of little dodges to assemble them, my story is in the link below.

That was errr about 7 years ago I think, they still sound wonderful

Cheers
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Old 17th July 2018, 04:58 PM   #1630
vitorio is offline vitorio  Spain
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Hi Fredrik

You can try OSB (Oriented Strand Board) 18mm. I did my pair from it and works well.

Cuts and glues very well, no nasty dust, very cheap. With a router you can round every corner and get acceptable finish tinted and varnished.
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