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Summer Project - Replication of MBL loudspeaker 101mkII
Summer Project - Replication of MBL loudspeaker 101mkII
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Old 21st September 2012, 09:59 PM   #1
Magnasanti is offline Magnasanti  United States
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Summer Project - Replication of MBL loudspeaker 101mkII
Default Summer Project - Replication of MBL loudspeaker 101mkII

I have a good 2 months out of school and i decided to build a replication of the loudspeakers MBL 101 mkII. The monetary resources to build a clone at least parts of it are taken care of . The following are the complete information of construction regarding the MBL 101 mkII. This project is inspired by this thread My MBL 101E replicas

DELAYED
The Tweeter :
Number Of Petals - 24
Lamella Material - Uni-Directional Carbon Fiber
Lamella - 24mm x Unknown
Lamella Bending Radius - 25mm
Lamella Type - Non-Stitched Epoxy Bonded
Lamella Resin - MGS System 285 (H287S MGS HARDENER SLOW)
Lamella - Bake Temperature And Pressure Unknown
Lamella Prepeg ratio - 54% Carbon Fiber 46% Epoxy Resin
Lamella Glue - unknown
Dampening - Polyester Fiber
(Twaron Angel hair)
Top Cap - W x 44.45mm
Top Cap Hole Diameter - Unknown
Mid Support Rod - W x L Unknown
Voice coil - Diameter 37mm ( 3.7cm )

Voice coil/Former - 4n Copper Wiring Used
Voice coil/Former - Aluminum Former Used
Voice coil/Former- Glue used is car break glue ''burned in at 500 Fahrenheit''
Voice coil/Former - Floats In Ferrofluid
Top Plate Diameter - 120.40mm
Bottom Plate Diameter - Unknown
Magnetic Material - Neodymium
Magnet size - 70mm ( 7cm )
Tweeter


Additional Known Driver Info

The outside of the lamellas are coated with a thin anti resonance film. The inside of the circular lamella configuration is filled with sound absorbing fibers witch have been confirmed to be of polyester origin.




IN-PROGRESS
The Mid-Range :
Number of petals - 12
Lamella material - Cross-Woven Carbon-Fiber
Lamella Tow - 1K
Lamella Type - Spread tow ( PrimeTex ZB )
Lamella cut - Bias
Lamella - 12.5mm x 1 sheet x 62mm
Lamella Bending Radius - 55mm
Lamella Resin - MGS System 285 (H287S MGS HARDENER SLOW)
Lamella - Bake Temperature 176F And Pressure 200psi
Lamella Prepeg Ratio - 54% Carbon Fiber 46% Epoxy Resin
Lamella Glue - Silicon Rubber Glue (Wacker)
Dampening - Polyester Fiber (Twaron Angel Hair)
Inner Ring- 40mm x 12.5mm
Inner-Ring Material - AL-MG ( Aluminum/Magnesium)
Inner-Ring Hole Diameter -
13mm
Outer-Ring - 90 x 12.5mm
Outer-Ring Material - AL-MG ( Aluminum/Magnesium)
Outer ring Hole diameter -
9.525mm ( 3/8" )
Inner-Hollow pass through -Rod - (OD)13mm x 5"
Inner-Hollow pass through -Rod (ID) 6.25mm
Inner-Hollow pass through -Rod Material - Graphite
Outer-Steel Support-Rod - 9.525mm ( 3/8" ) x 60mm ( 6cm )
Outer-Support-Rod Material - Super-Refined Steel
Voice coil Diameter - 5cm ( 50mm )
Voice coil/Former - 4n copper wiring used
Voice coil/Former - Kapton former used
Voice coil/Former- Glue used is car break glue ''burned in at 500 Fahrenheit''
Voice coil/Former - Floats In Ferro-Fluid
Top Plate Diameter - Unknown
Bottom Plate Diameter - Unknown
Magnet material - Neodymium
Magnet size - 12cm ( 120mm )
Mid-Range


Additional Known Driver Info


The thrust bearing is a single side coated with a heavy tar plate to reduce resonance. The inside of the lamella group is coated with a special rubber material, and thin anti resonance film is also applied to the lamellas. The four rods are super refined steel. Both ends of the lamellas are glued using the silicon rubber glue, all the lamellas are glue together with a bead. polyester fiber fills the inside, and is sealed off by a rubber material.




Delayed
The Melon :
Number of petals - 12
Lamella material - an alloy of Aluminum,magnesium,and silicon
Alloy ratio - Unknown
Lamella - Raw 50mm widest point x 20mm at end points x D x 360mm
Lamella - Assembled 10in x D x 16.5in with a lamella end of 4inch
Lamella Glue - Silicon Rubber
Lamella Bending Radius - Unknown
Dampening - Polyurethane Foam/Polyester Fiber
Copper Rods - L x W Unknown
Top Cap - W x D x L Unknown
Top Cap Hole Diameter -Unknown
Mid- Hollow -Rod - W x D x L Unknown
Voice coil Diameter -
100mm OD (10cm)
Voice coil/Former - 4n copper wiring used Likely
Voice coil/Former- Glue used is car break glue Likely
Voice coil/Former - Former Used Unknown
Voice coil/Former - floats in Ferrofluid likely
Magnetic Material - Ferrite
Magnet size - 200mm OD (20cm)
Spider ID-OD - 100mm (10cm)
Melon
Additional Driver Info

The aluminum lamellas are a sandwich construction of two aluminum wedges held with epoxy resin Wrong. The petals are given 2 days to cool like airplane parts. layers of polyurethane foam are slapped on the back of each lamella to provide damping and additional mass. Each lamella is fitted with 2 thick reddish copper ''wires''. The wires are fitted into the vertical recesses of the petal. The wires add mass and an aesthetic beauty. The recesses of the driver are rolled and not stamped. The whole assembly rest on a cast aluminum plinth coated in automotive grade atracite metallic paint.

The sub woofer
The woofer is a 12" driver with a 4" voice coil. The voice coil is composed of black anodized aluminum that has a very low thermal resistance, approximately 1 K/W. This gives the system large power handling capability. The voice coil wire is also constructed of high temperature material able to withstand temperatures of up to 360¡C. The wire is glued with the same glue used in the fabrication of motorcycle brakes, and is able to withstand a temperature of 260¡C. As a result, it is almost impossible to destroy the speaker. The air gap is 10 mm high and the moving coil has a winding width of 24 mm. Thus, the speaker possesses an extremely high linear throw, with a maximum of 14-mm peak to peak. The maximum mechanical throw is two times greater -- 28 mm maximum peak to peak.
For this i hope to substitute for this driver
TC Sounds Axis 12Q1 12" Quad VC Subwoofer 293-638


The cabinet :
Material - MDF
Material thickness - 30mm (1.25")
Port Holes - 2 inches in Diameter

Additional cabinet info
the cabinet has rectangular cross configuration to both stabilize the walls and hold the magnet with polyurethane supports.

specifications:
Crossover frequencies: 105Hz, 600Hz, 3.5kHz (Linkwitz-Riley, fourth-order). Acoustic center: 45" (1140mm) from floor. Frequency range: 24Hz–40kHz. Sensitivity: 81dB/2.83V/m. Nominal impedance: 4 ohms. Power handling: 320–500W continuous, 2.2kW peak.

Right now i am hopping to simply replicate the mid-range and used them as my stereo setup and as research and design along with resources progress the replication of the other 2 drivers will begin. I am learning to use Femm so that i can design and build the magnetic circuit for the mid range.The processes for building the mid range will hopefully be done in parts such as

Step 1 : Magnetic circuit fully designed and optimized in femm

Step 2 : ferrofluid properties such as viscosity,heat tolerance,and Gauss rating can then be calculated

Step 3 : Carbon fiber baking methods can be R&D

Please tell me your thoughts on such a project

Last edited by Magnasanti; 13th November 2012 at 06:34 PM.
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Old 21st September 2012, 10:03 PM   #2
Magnasanti is offline Magnasanti  United States
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Summer Project - Replication of MBL loudspeaker 101mkII
Default Pictures shedding light on Speaker construction

The Tweeter
Attached Images
File Type: jpg 101.jpg (39.9 KB, 2635 views)
File Type: jpg mblconstruction.jpg (64.4 KB, 2583 views)
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Old 21st September 2012, 10:07 PM   #3
Magnasanti is offline Magnasanti  United States
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Summer Project - Replication of MBL loudspeaker 101mkII
Default Mid-Range naked

Construction of the mid range.
Attached Images
File Type: jpg Mbl mid Baked sheet of carbon fiber.jpg (18.7 KB, 2533 views)
File Type: jpg Mbl mid - computer cut lamnella.jpg (13.1 KB, 2495 views)
File Type: jpg MBl assembly of the mid-range.jpg (33.4 KB, 2489 views)
File Type: jpg Mbl mid the petals are glued to the voice coil and thrust plate.jpg (14.8 KB, 679 views)
File Type: jpg Mbl mid partially asmebled with thrust plate held in place.jpg (14.9 KB, 493 views)
File Type: jpg resan8038.jpg (43.1 KB, 733 views)
File Type: jpg Mbl naked mids 3.jpg (27.9 KB, 730 views)
File Type: jpg Mbl Mids Single.jpg (380.9 KB, 765 views)
File Type: jpg mid-range inner workings.jpg (28.1 KB, 786 views)
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Old 21st September 2012, 10:10 PM   #4
Magnasanti is offline Magnasanti  United States
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Summer Project - Replication of MBL loudspeaker 101mkII
Default The Melon naked

The Melon construction
Attached Images
File Type: jpg Mbl melon lamnella.jpg (34.9 KB, 715 views)
File Type: jpg Mbl melon lamnella after rolled corrigation.jpg (14.2 KB, 510 views)
File Type: jpg Mbl melon lamnella after dampening has been applied.jpg (14.9 KB, 382 views)
File Type: jpg showing dampening.jpg (36.3 KB, 433 views)
File Type: gif Mbl melon parts.gif (37.6 KB, 476 views)
File Type: jpg mbl naked 4.JPG (158.2 KB, 659 views)
File Type: jpg mbl melon the black elastic bands are being put on and so is external dampening.jpg (20.0 KB, 589 views)
File Type: jpg Mbl Naked 6.JPG (152.3 KB, 551 views)
File Type: jpg mbl melon beinge flued to thrust plate and motor sytem.jpg (25.0 KB, 554 views)
File Type: jpg putting on lamellas.jpg (44.9 KB, 515 views)
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Old 21st September 2012, 10:11 PM   #5
Magnasanti is offline Magnasanti  United States
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Summer Project - Replication of MBL loudspeaker 101mkII
Default The Melon naked Con't

The melon construction
Attached Images
File Type: jpg Adjusting voice coil wire.jpg (368.1 KB, 549 views)
File Type: jpg putting on lamellas.jpg (44.9 KB, 286 views)
File Type: jpg melon wires.jpg (161.3 KB, 470 views)
File Type: jpg mbl_rundstralere_11.jpg (127.5 KB, 476 views)
File Type: jpg Mbl naked melons 8.jpg (21.7 KB, 272 views)
File Type: gif MBL naked all.gif (21.2 KB, 314 views)
File Type: jpg mbl melon naked 3.JPG (155.6 KB, 431 views)
File Type: gif Mbl head cut off.gif (31.7 KB, 423 views)
File Type: jpg showing spider.jpg (28.0 KB, 433 views)
File Type: jpg Guy holding completed Melon.JPG (39.7 KB, 553 views)
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Old 21st September 2012, 10:14 PM   #6
Magnasanti is offline Magnasanti  United States
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Join Date: May 2012
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Summer Project - Replication of MBL loudspeaker 101mkII
Default Areczek finished speakers

Pictures of Areczeks finished speakers
Attached Images
File Type: jpg Areczeks completed Mbl clones.jpg (199.6 KB, 687 views)
File Type: jpg Mbl areczek.jpg (195.2 KB, 654 views)
File Type: jpg Omni''grand melone''.JPG (172.2 KB, 544 views)
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Old 21st September 2012, 10:15 PM   #7
Magnasanti is offline Magnasanti  United States
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Summer Project - Replication of MBL loudspeaker 101mkII
Default Driver choice

Mid Range is the Dayton Audio Rs52an-8 2" Dome Mid range.

Attached Images
File Type: jpg 285-020_m.jpg (1.2 KB, 2707 views)
File Type: jpg 285-020_mii.jpg (1.4 KB, 2697 views)
File Type: jpg 285-020_mi.jpg (1.3 KB, 2694 views)

Last edited by Magnasanti; 21st September 2012 at 10:26 PM.
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Old 21st September 2012, 10:16 PM   #8
Magnasanti is offline Magnasanti  United States
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Summer Project - Replication of MBL loudspeaker 101mkII
Default Dayton Anotomy

Dayton mid range taken apart.
Attached Images
File Type: jpg IMG054.jpg (497.2 KB, 452 views)
File Type: jpg IMG056.jpg (402.9 KB, 299 views)
File Type: jpg IMG057(1).jpg (470.1 KB, 314 views)
File Type: jpg IMG060.jpg (436.0 KB, 350 views)
File Type: jpg IMG058(1).jpg (363.5 KB, 604 views)

Last edited by Magnasanti; 21st September 2012 at 10:28 PM.
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Old 21st September 2012, 10:17 PM   #9
Magnasanti is offline Magnasanti  United States
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Summer Project - Replication of MBL loudspeaker 101mkII
Default Models of drivers

A MS paint illustration showing mid range driver components.
Attached Images
File Type: png Mid-Range model.png (67.0 KB, 844 views)
File Type: png Tweeter 1.png (127.8 KB, 670 views)

Last edited by Magnasanti; 21st September 2012 at 10:30 PM.
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Old 24th September 2012, 02:34 AM   #10
bear is offline bear
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Summer Project - Replication of MBL loudspeaker 101mkII
Does it make sound?
Does it not fall apart?

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http://www.bearlabs.com -- Btw, I don't actually know anything, FYI -- every once in a while I say something that makes sense... ]
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