2 way Synergy inspired by SPL Runt

DAS M50 converted from screw on to flange mount. Using a 3D printer and two M6 hex head screw.

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The LF driver will be most probably Fane Sovereign 8-225, which worked really fine not only in this design, but also in the "Kallax" MEH I built. The Pro version is only slightly more expensive. It offers a cast basket, push terminals and better controlled FR.

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My only concern is that the datasheet of the Pro version says that rear mounting is N/A. Is there any problem I could expect with this style of basket when mounting from the rear on the horn? If not, I will go for the Pro version.
 
Drivers arrived, testing the cone filler profile. Good enough I would say - without using too many curves.

The front seal is 3 mm thick, so a ring of 2.4 mm HDF board should be just perfect for mounting on the horn panel.
 

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So the 3D printed jig worked quite well...not perfectly, it would need some more tuning and I was not patient enough. It was much easier and quicker to glue all 4 sides at once, but I overtightened the clamps a bit and had a bit of slide on the side panels. The first one ended up being ca 2 mm wider, the second one is ca 2 mm narrower than the 3D model. So before building the box around them, I will have to build a small frame around to compensate for the difference. And also lots of putty goes to the gaps.

In the end, I am pretty happy at least the front is square. The first one made from MDF was far from square. If I ever build another pair, it will be even better🙂
 

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Definitely, Johannes619 is using them with kicks and subs (he might provide more detail on them), my pair will be for home use with less max SPL - only with a mono subwoofer.

Having a pair of these with one kick and two subs per side makes a pretty nice PA.
 
I have used my accumulator powered electric planer for the first time. What a wonderful (and dangerous) tool it is. I planed down the wider horn sides in a few minuter, so both will be the same width. I learned the hard way to make one pass and measure. The wider horn will be asymmetrical by a millimeter or two and I had to plane down the sides of the narrower horn as well.

But now the mission is accomplished and both will fit into a box of identical dimensions without making a special frame around each horn.
 
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Work in progress🙂 Cutting parts for the box on the CNC. Tomorrow, I should have all parts for one box done. Sides will be 18 mm including access doors, top, bottom and back will be 12 mm. Just using what I have at hand, no other reason for that. The back will have 200 x 200 VESA mounting points so that the boxes can be mounted on a extendable TV holder.
 

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Some more progress today. Bottom, horn and sides including the access panels. Tested that they are large enough for comfortable manipulation inside.

Since I am cutting the rectangular panels on a CNC, I started to appreciate the drawing functions of CamBam. Panels like these can be drawn and have gcode produced in a very short time. I have all the parts cut with the exception of 4 18 mm braces for the Vesa mount - to hold the T-nuts in place.
 

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