Crossover construction techniques - diyAudio
Go Back   Home > Forums > Loudspeakers > Multi-Way

Multi-Way Conventional loudspeakers with crossovers

Please consider donating to help us continue to serve you.

Ads on/off / Custom Title / More PMs / More album space / Advanced printing & mass image saving
Reply
 
Thread Tools Search this Thread
Old 19th April 2009, 12:42 AM   #1
diyAudio Member
 
Join Date: Dec 2006
Default Crossover construction techniques

Hi,

I've been *slowly* putting together a couple of bookshelf speakers and was wondering if anyone could give me some advice regarding the physical construction of crossovers.

Due to the size of the caps and inductors I'm thinking its better to secure them on a more solid surface than a PCB and wire them up point to point. Is this the general way it is done?

Thanks in advance
  Reply With Quote
Old 19th April 2009, 01:35 AM   #2
diyAudio Member
 
Join Date: Dec 2006
Location: Where the sky loves the sea
I built a pcb and used hot glue to secure the coils after soldering them. Or you can use zip ties through the board.

Also remember to orient the coils to minimize coupling between them.
  Reply With Quote
Old 19th April 2009, 01:39 AM   #3
diyAudio Member
 
Join Date: Dec 2006
Location: Where the sky loves the sea
Here's an example pcb layout. It mounts on the binding posts - physical mounting and electrical connection all in one.
Attached Files
File Type: pdf xoverpcb.pdf (23.8 KB, 125 views)
  Reply With Quote
Old 19th April 2009, 04:02 AM   #4
tinitus is offline tinitus  Europe
diyAudio Moderator R.I.P.
 
Join Date: Nov 2005
Would help to see how your schematic is done

I always draw my schematic logically like this

And I find the best way to layout the components is exactly the way its done in schematic

On a piece of wood is fine

Use solidcore copperwire fore all "lines", mounted at the ends either through small wood "blocks" or solder terminals

I dont twist leads but just solder them together, very carefully

Fore mounting components I use polyurethane foam glue

If one driver(tweeter) needs to be reversed, I prefer to do it at output of filter, others do it at driver terminals
Attached Images
File Type: jpg 2 vejs.jpg (21.7 KB, 493 views)
__________________
sometimes we know very little, and sometimes we know too much
  Reply With Quote
Old 19th April 2009, 07:24 AM   #5
diyAudio Member
 
Join Date: Dec 2006
Thanks for the ideas and help!

Just wondering, why don't people mount the crossovers in an external enclosure and run seperate leads to each driver. Wouldnt that be a much more ideal scenario? Is it just plain practicality that prevents this or am i missing something?
  Reply With Quote
Old 19th April 2009, 09:57 AM   #6
SY is offline SY  United States
diyAudio Moderator
 
SY's Avatar
 
Join Date: Oct 2002
Location: Chicagoland
Blog Entries: 1
I did that with the last set of dynamic speakers that I designed. It makes circuit changes much easier and eliminates any possibility of microphonics from loosely wound coils or caps. It does, though, mean lots of wires coming out of the back of the speaker cabinets.
__________________
You might be screaming "No, no, no" and all they hear is "Who wants cake?" Let me tell you something: They all do. They all want cake.- Wilford Brimley
  Reply With Quote
Old 20th April 2009, 12:34 AM   #7
wlowes is offline wlowes  Canada
diyAudio Member
 
wlowes's Avatar
 
Join Date: Mar 2007
Location: Toronto
Blog Entries: 9
Default crossover design

I just finished my first crossover, and I must say that I am very happy with my results.

The original xover was mounted on a piece of fibre board inside the speaker cabinet.

I built my replacement with high quality parts mounted on a 1 inch thick piece of oak plank. The parts were secured with a glue gun to the wood. I drilled holes into the wood and ancored the capacitors and resistor leads with hot glue and or epoxy into the wood. Then I wired it point to point with unshielded solid silver and copper wires. The crossover boards sit on the floor behind the speakers, and are wired to the drivers via separate solid wires. They sit on a sheet of bubble wrap to further insulate them from vibration.

I took an unconventional approach with the caps and used NOS BlackGate AC as opposed to the conventional wisdom of exotic film caps. 2 reasons. The BG AC had been listed in many posts as being as good as all but the best Mundorf Silver/Gold in Oil versions, and they are a fraction the price. Also the rest of my System is Black Gate equipped, and it just seemed kind of cool to have a tribute to the Black Gate legend. I used MILS resistors. The BG's do take a while to burn in. Right at first the improvement was dramatic. My system was already pretty well defined with a fully 3d sound stage and no apparrent speakers in the presentation. The new xover immediately moved mids and highs to clear and clean presentation. The last of symbols sounding more like polywrap being crunched was replaced by shimmering brass. I ran it for about 100 hours. It is now unbelievably opened up and cyristal clear. The sound stage is hudge and 3d airy. Voices are human and pianos are pianos. As I write this I'm listening to a guitar that is spooky real. Cello solo's are alive and vibrant.

I guess my message in all this is I listened to advice on the DIY forums and it worked for me. The advice was:
Put the xover outside the box.
Hard wire and solder everything. Strong physical connection / crimp first and a little solder to keep it that way.
Solid core wire everywhere in the signal path.
I like copper and pure silver. I use small guage 28awg for the high frequency and much larger copper for the lower registers.
Check out the capcitor shoot out pages and choose high value within your budget and expect them to take a while to reach their potential.
As with everything, keep vibration to a minimum.

Hope this helps.
  Reply With Quote
Old 20th April 2009, 02:57 AM   #8
Ron E is offline Ron E  United States
diyAudio Member
 
Ron E's Avatar
 
Join Date: Jun 2002
Location: USA, MN
My last set I free-wired each section, tucked/bent them into a small package and velcroed them to a cabinet wall, separated a bit.
__________________
Our species needs, and deserves, a citizenry with minds wide awake and a basic understanding of how the world works. --Carl Sagan
Armaments, universal debt, and planned obsolescence--those are the three pillars of Western prosperity. Aldous Huxley
  Reply With Quote
Old 22nd April 2009, 10:17 PM   #9
diyAudio Member
 
Join Date: Dec 2006
Thanks everyone just the advice I needed I've actually headed down the path of a shielded enclosure which was surplus from work and figure because the crossover point is at a pretty common point for a two way (3kHz) I could use it to do preliminary testing on new designs.

Thanks again!
  Reply With Quote
Old 22nd April 2009, 10:39 PM   #10
tinitus is offline tinitus  Europe
diyAudio Moderator R.I.P.
 
Join Date: Nov 2005
Quote:
Originally posted by wiredmonkey

headed down the path of a shielded enclosure

Thanks again!

Iron is a big nono, but even aluminium affects the coils

Take a look here, and study very carefully, it is priceless information

http://www.troelsgravesen.dk/coils.htm
__________________
sometimes we know very little, and sometimes we know too much
  Reply With Quote

Reply


Hide this!Advertise here!
Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off


Similar Threads
Thread Thread Starter Forum Replies Last Post
Construction techniques for thick clear plastic? jaylgordon Construction Tips 10 24th April 2009 03:15 PM
Baffle Construction Techniques coolkhoa Multi-Way 21 4th September 2006 09:34 PM
Construction Techniques(putting DIY in a proper enclosure) TomWaits Solid State 38 23rd May 2006 02:20 AM
Case Construction Techniques Devil_H@ck Everything Else 30 18th September 2004 04:24 PM
Subhorn Construction techniques? mikee12345 Multi-Way 6 2nd December 2003 02:41 AM


New To Site? Need Help?

All times are GMT. The time now is 04:55 AM.


vBulletin Optimisation provided by vB Optimise (Pro) - vBulletin Mods & Addons Copyright © 2014 DragonByte Technologies Ltd.
Copyright 1999-2014 diyAudio

Content Relevant URLs by vBSEO 3.3.2