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Old 15th September 2013, 07:57 PM   #11
Bigun is offline Bigun  Canada
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I had a bash at some routing. It's been a year since I built the Big'un speaker and as a result it took hours to locate the relevant tools

Still, I managed to find it all. First image you see the set-up, with a drill bit sticking out as the centre-pin which pokes through a strategically placed hole in the scrap wood screwed to the base of my router to ensure the right diameter circle. I erred on the generous size for the outer circle to get a diameter of order 168mm and a rebate depth of a hair over 12mm. The inner circle, the cut-out, is something of worry because if you make this generous there's a risk of not leaving enough land for the mounting screws. The Alpair drivers have very little tolerance in this regard. I opted to under-size slightly at around 134mm diameter. I'll then manually enlarge the cut-out to suit the plastic frame supports. My router doesn't go through the total baffle thickness so I had to turn the pieces over and route from the back to complete the cut-out. To get the front and back cut-outs to line up you need to drill a perpendicular hole in the centre for the centre-pin. I managed to do a good job of this on one baffle, but the other was out (I really do need a drill press).

And the chamfers at the backside are done too.
Attached Images
File Type: jpg setup.JPG (238.7 KB, 215 views)
File Type: jpg backClearance.JPG (91.6 KB, 214 views)
File Type: jpg frontpanel.JPG (85.9 KB, 209 views)
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Old 16th September 2013, 04:24 PM   #12
chrisb is offline chrisb  Canada
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fun, huh?
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Old 17th September 2013, 12:28 AM   #13
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Has anybody figured out how to do the scallops without setting fire to the baffle?

I do like the two-stage chamfer. I might try that.

Bob
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Old 17th September 2013, 12:43 AM   #14
Bigun is offline Bigun  Canada
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Quote:
Originally Posted by Bob Brines View Post
Has anybody figured out how to do the scallops without setting fire to the baffle?
It's a sign of serious DIY


Quote:
Originally Posted by Bob Brines View Post
I do like the two-stage chamfer. I might try that.
It wasn't the intent when I started
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Old 17th September 2013, 03:34 PM   #15
chrisb is offline chrisb  Canada
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Quote:
Originally Posted by Bob Brines View Post
Has anybody figured out how to do the scallops without setting fire to the baffle?
CNC router and very careful alignment ?

when I care enough about it, I'll just tidy up with some 80G PSA sandpaper wrapped on a scrap of 1 1/4" closet rod

Quote:

I do like the two-stage chamfer. I might try that.

Bob
I think that was accidental?
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Old 17th September 2013, 11:39 PM   #16
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Quote:
Originally Posted by Bob Brines View Post
Has anybody figured out how to do the scallops without setting fire to the baffle?

I do like the two-stage chamfer. I might try that.

Bob
Frankly i prefer a gouge, rasp and a few lines
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Old 18th September 2013, 01:38 AM   #17
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Quote:
Originally Posted by paul burchell View Post
Frankly i prefer a gouge, rasp and a few lines
Do you do a few lines before or after you work on your speakers?

Bob
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Old 18th September 2013, 08:58 AM   #18
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Quote:
Originally Posted by Bob Brines View Post
Do you do a few lines before or after you work on your speakers?

Bob
Sorry i ment to say a gouge,rasp then a few line
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Old 18th September 2013, 12:40 PM   #19
Bigun is offline Bigun  Canada
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I usually deliver a few lines with a bit of a rasp
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Old 21st September 2013, 02:34 PM   #20
Bigun is offline Bigun  Canada
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Some progress has been made on the porta-bench in my driveway

A couple of holey braces were positioned starting just below the driver cut-out where I want to stiffen things the most. Both braces are vertical, one front-to-back and the other side-to-side.

I then installed a number of other criss-cross braces from left over 2" wide 'sticks'. In particular I wanted to brace the port opening against the back of the box since the open edge is not supported otherwise.

I installed some thick felt lining around the inside of the top part of the box to tame high frequency reflections.

The driver has been dry-fitted to test the opening dimensions.

I'm probably about half way through the work effort now. It needs A LOT of tidying up before it looks presentable.
Attached Images
File Type: jpg holeybrace.JPG (156.9 KB, 105 views)
File Type: jpg crisscross bracing.JPG (89.3 KB, 103 views)
File Type: jpg thick felt lining around driver.JPG (186.9 KB, 35 views)
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