OK...first of all let me say this....
For years before I was even considering DIY audio, I bought a pair of ACI (Audio Concepts Inc) Sapphire III's from my little brother.
Probably the most impressive thing about these speakers were the cabinets, they were made from 1 inch HDF! (High Density Fiber board.) The knock test on these makes everything else seem amateur!
To make a long story short when I decided to build my own speakers, naturally I wanted HDF! But we had huge problems there.
The problem wasn't just not being able to find it, nobody even knows what it is!!!! But with a diligent internet search and a LOT of CREATIVITY I found the hands down solution to building speaker cabinets with HDF !!! No JOKE!
Let me clarify right here I am working out some details but my first test seems like it will work WITHOUT improving anything from my first trial.
Okay so here goes.
I am currently building the popular Elsinores project. And in one post Joe mentioned one of the biggest improvements you could make to the cabinet was to build just the front panel out of HDF!
"But the thing that I believe would improve the box most is the most simple (and yet difficult at the same time), take a look at the newer Dynaudio designs, that baffle of theirs made of high density fibre board. I have heard a pair of Lenehan ML-1 speakers in both standard and 'Signature' versions and this was the only difference. Make the front part of the box structure out of this material and I believe the improvement would be greater than anything I have covered so far, no kidding!" (
http://www.diyaudio.com/forums/multi-way/97043-elsinore-project-thread-15.html)
So I have spent the last several weeks...not to mention several years trying to source HDF! But it wasn't happening! You can get it but you have to buy a few thousand dollars worth of inventory!
But I did find something called "hardboard". And as it turns out it is the same thing as HDF, but it's just come is thin sheets.
So I got the idea of laminating several sheets together to make the thickness needed to build a cabinet!
So I bought a sheet of it, ripped the sizes I needed and this afternoon laminated them together...and all I can say is WOW!
WOW, WOW, WOW!!!!
On a single 9" X 4' panel the knock test hurts your knuckles! I am not kidding! It is like concrete, without any bracing of even a structure! For speaker building I think it was the smartest move I've made!
I used 7 total 1"x 4"s with braces behind them and my test piece is not as straight as I'd like. Which I am sure once even thing is put together would not be a problem, but tomorrow I'm going to get a half sheet (4' x 4') of 1/2" hardwood plywood and make a "former" to keep the rest of the laminations straighter!
I'll update when I have more to tell...and pictures.