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Old 2nd January 2014, 10:09 PM   #1
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Default One.20 Construction Diary

Hi everyone and happy 2014 to you all.

A new year and a new build log. With my last build complete - the Apollo, I can now turn my attention fully to something I've been working on for the past couple of years.

There's been many iterations and a few prototypes made, all progressively better than the last but none quite satisfying me completely. One thing I've really had a lot of success with is casting the parts out of composite resin (a polyurethane type with an aluminium oxide filler component for added mass). This stuff is brilliant for audio applications, its basically making your own solid surface(aka corian). I did the baffle first with regular, albeit heavily braced, wood based cabinets but really wanted to go ahead and make a complete composite resin speaker. This is what this build thread is about.

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The baffle plugs are already done. These are a two sided part.

Front side on the CNC:
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Rear:
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They aren't suitable for use in making a mold straight off the machine so have to be sanded and finished. Basically the better the finish here the better your mold and any parts cast using it will be

Click the image to open in full size.

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Here's a video showing the process involved in creating the plugs to be used in making the molds for the baffles using CNC.

CNC Cutting Loudspeaker Baffles - YouTube

The cabinet sections will be done in a similar fashion with the exception that they'll be broken into two halves and the cast parts will be joined to form a complete cabinet. Not only will they be incredibly inert but also allow for some pretty radical internal contouring and bracing thanks to the flexible nature of CNC machining.

More to come over the next few months.
Attached Images
File Type: jpg 20130802_195320.jpg (102.8 KB, 979 views)
File Type: jpg 20130802_195528.jpg (116.2 KB, 973 views)
File Type: jpg Baffle Masters 11.jpg (112.7 KB, 986 views)
File Type: jpg Baffle Masters 06.jpg (92.1 KB, 962 views)
File Type: jpg One.231.jpg (83.3 KB, 979 views)
File Type: jpg One.232.jpg (91.8 KB, 970 views)
File Type: jpg One.233.jpg (73.3 KB, 961 views)
File Type: jpg One.235.jpg (80.0 KB, 979 views)
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Old 2nd January 2014, 10:35 PM   #2
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Your construction is the tits.
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Old 2nd January 2014, 11:44 PM   #3
ScottG is offline ScottG  United States
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Quote:
Originally Posted by ShinOBIWAN View Post

..One thing I've really had a lot of success with is casting the parts out of composite resin (a polyurethane type with an aluminium oxide filler component for added mass). This stuff is brilliant for audio applications, its basically making your own solid surface(aka corian).
What, 6 years in the "making"?

Still, a bit different than cement.


Regardless, very and something I'll be very interested in reading.


Happy New Year!
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Old 3rd January 2014, 02:08 AM   #4
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Originally Posted by H E Pennypacker View Post
Your construction is the tits.
This. (I was searching for the right words.)
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Old 3rd January 2014, 02:57 PM   #5
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Thanks guys.

Here's the guts:

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File Type: jpg One.241.jpg (137.7 KB, 956 views)
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Old 3rd January 2014, 11:09 PM   #6
ScottG is offline ScottG  United States
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Oh my, its naked!




I've a request for this thread (or two actually)..

A video on the some small portion of the complex baffle's creation in your CAD (..Solidworks, right?)

..also,

Another video on the completed design being altered for making molds.


..please.
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Old 4th January 2014, 02:08 AM   #7
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Amazing work!
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Old 4th January 2014, 05:12 AM   #8
ScottG is offline ScottG  United States
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Originally Posted by mayhem13 View Post
Amazing work!
..yup, and renders too!
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Old 5th January 2014, 01:34 AM   #9
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Originally Posted by ScottG View Post
I've a request for this thread (or two actually)..
I'll try at some point Scott. I'm limited on time these days now things have gotten more serious and I've got 2 big projects in the works right now.

If your looking for anything specific ask away and I'll help out as best I can.
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Old 5th January 2014, 01:55 AM   #10
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This build thread might end up covering the One.10 standmount instead of the larger One.20. At least to start with anyway.

I do have some reasoning behind this. Its my first shot at casting and a smaller casting is easier and cheaper. I've had a go casting a bunch of smaller parts and now I have a vacuum degassing chamber and pump they're looking good but haven't tried anything on this scale yet. Its a slightly scary proposition really as there's nearly 400 worth of addition cure silicon rubber used for the One.20 baffle alone and once you start pouring a mould, there's no going back!

Anyhow here's the One.10 and its stand. I'll likely cast the stand out of resin as well although this will be a thinner wall thickness compared to the cabinets and allow for added mass in the column (lead shot, sand etc.)

Click the image to open in full size.

Click the image to open in full size.

Click the image to open in full size.
Attached Images
File Type: jpg One.253.jpg (102.0 KB, 766 views)
File Type: jpg One.258.jpg (75.4 KB, 749 views)
File Type: jpg One.255.jpg (90.9 KB, 764 views)
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