I have started on a fullrange summer adventure and could use some tips. I just finished a quick set of Pensil70s and they sound great. My construction skills suck though. I know practice makes perfect so I am plugging along.
A few questions I have for the experts:
1) What is the best/easiest way to cut angles for horns and such?
2) Where do you generally start when glueing together?
3) Got any tips on keeping every thing straight?
4) When building these speakers with all the angles inside do you just clamp on peice at a time to one of the sides and then sandwich?
Any pointers would be fantastic.
Thanks
Kris
A few questions I have for the experts:
1) What is the best/easiest way to cut angles for horns and such?
2) Where do you generally start when glueing together?
3) Got any tips on keeping every thing straight?
4) When building these speakers with all the angles inside do you just clamp on peice at a time to one of the sides and then sandwich?
Any pointers would be fantastic.
Thanks
Kris
smooth talker
for me these two depend on the design, which can often be slightly modified to simplify construction/assembly sequence, as well as the available tools and your confidence in using them.
do you have a particular design in mind?
most of the horns/BVR etc that I build are narrow enough that a sliding tenon jig for table saw does a perfect job of holding workpiece securely in place for cuts more acute than 45deg
aside from the obvious to ensure that all cuts are at the prescribed angles, and dimensions? (don't assume that the bevel gauges or calibration of the rip fence on your table saw are accurate) - a separate cheap digital angle gauge, tape measure and square are vital
I'm a great fan of air powered brad nailer and 3M 1" masking tape to hold some of the sub-assemblies in place - even if you had the requisite clamps, there's often not enough room to fit them all.
have fun gleaning from the bushels of helpful advice you're about to receive
Last edited:
Hi Chris
Thanks for the response.
Cool I thought I was cheating using the brad nailer.
Its funny I feel pretty comfortable making the cuts but once I try to put the box together I lose all composure.
thanks again
Kris
Thanks for the response.
I am thinking of trying out the Lotus for the CHR-70 because a) I have the drivers and b) I like the sound of them. I have also been looking at the 'onkens for the A7.
Cool I thought I was cheating using the brad nailer.
Its funny I feel pretty comfortable making the cuts but once I try to put the box together I lose all composure.
thanks again
Kris
I've not yet built Lotus, and just finished a quick protoype of Maeshowe ( drivers not yet installed), but I can say that while the 'onken prime series is a bit of a fiddly and time consuming build, after well over a couple of dozen pairs with various CSS, Fostex and Mark Audio drivers they are definitely worth the effort
I think Dave may have recently revised the drawings? - if for no other detail than the moniker 😱
no such thing as cheating in DIY (just keep your fingers out of the way - flesh is a lot softer than plywood) and FWIW, I like to spend my time on the veneering and finishing
just take your time and enjoy the mistakes, oops I meant learning opportunities
Cutting wood straight and having consistent dimensions are a skill. I definitely would use a brad nailer. Also, quadruple check your calculations before you cut anything. If you are using a table saw...google anything having to do with aligning a table saw blade. A table saw sled jig is a good trick to getting smooth, even cuts. Make one if you can...not that hard.
I myself will be starting soon to cut the cabinets for the Troels DQWTL speaker. There are braces and transmission line panels which will be internal...and seem a little tricky. But hey...if things were easy to make...you would not appreciate them as much when its over.
Cheers
Hi
1) What is the best/easiest way to cut angles for horns and such?
Using a powered saw with an adjustable blade angle and a bench where you can hold the wood firmly in place.
2) Where do you generally start when glueing together?
I normally glue the sides to the top and bottom and later fit the insides then the front and back.
3) Got any tips on keeping every thing straight?
You put a cabinet ( picture frame ) cramp around the top, bottom and two sides. A cabinet cramp consists of four metal 90 degree corner brackets with a wire cable around them that is tightened by turnscrew. When the cramp is in place square the sides and leave untill the glue sets. ( These cramps are cheap to buy and it is very difficult to manage without them )
4) When building these speakers with all the angles inside do you just clamp on peice at a time to one of the sides and then sandwich?
See above
5) I think it is usually best to use a wood glue that will soak into the wood to make the joints strong and then use wood blocks glued along the inside of the joints to give strength to the joint.
Don
1) What is the best/easiest way to cut angles for horns and such?
Using a powered saw with an adjustable blade angle and a bench where you can hold the wood firmly in place.
2) Where do you generally start when glueing together?
I normally glue the sides to the top and bottom and later fit the insides then the front and back.
3) Got any tips on keeping every thing straight?
You put a cabinet ( picture frame ) cramp around the top, bottom and two sides. A cabinet cramp consists of four metal 90 degree corner brackets with a wire cable around them that is tightened by turnscrew. When the cramp is in place square the sides and leave untill the glue sets. ( These cramps are cheap to buy and it is very difficult to manage without them )
4) When building these speakers with all the angles inside do you just clamp on peice at a time to one of the sides and then sandwich?
See above
5) I think it is usually best to use a wood glue that will soak into the wood to make the joints strong and then use wood blocks glued along the inside of the joints to give strength to the joint.
Don
Don...
Using a table saw is probably the easiest way. But you have to make sure that the blade is aligned correctly so as to cut a straight line. Also, the table saw fence needs to be able to lock in place securely. Waxing the surface of the table will make the wood glide over the surface...making cuts even easier to control.
Wood glue is the best choice for any wood. I believe that if you were to cut the side panels first, then lay all the interior pieces vertically onto the side panel...secure them into place with glue or even tape...you could then place the opposing side panel on top...then nail/screw/etc down. The important part is to make precise, carefully measurements first. Google woodworking topics and you will find a plethora of information including videos on how to make cabinets and similar items. The inside needs to be sealed with either glue or silicon or similar. Wood blocks also help to strengthen the joints.
Cheers
Using a table saw is probably the easiest way. But you have to make sure that the blade is aligned correctly so as to cut a straight line. Also, the table saw fence needs to be able to lock in place securely. Waxing the surface of the table will make the wood glide over the surface...making cuts even easier to control.
Wood glue is the best choice for any wood. I believe that if you were to cut the side panels first, then lay all the interior pieces vertically onto the side panel...secure them into place with glue or even tape...you could then place the opposing side panel on top...then nail/screw/etc down. The important part is to make precise, carefully measurements first. Google woodworking topics and you will find a plethora of information including videos on how to make cabinets and similar items. The inside needs to be sealed with either glue or silicon or similar. Wood blocks also help to strengthen the joints.
Cheers
Probably lots of people already know this stuff, but here's some info I've picked up...
Use a sawboard. Don't try to make one out of wood, though. I got an aluminum cutting guide from Home Depot for $20. The wooden one I tried to make had an ever-so-slight bow... not enough to easily see, just enough to screw things up!
Router + Flush trim bit. Oversize some bits of your cabinet, then trim them down after you've affixed them in place. Finding the way to use this bit of advice on your particular project is left as an exercise for the reader...
Just nail things into place. The builds I try to do clamp-only always slide around just a little. I'm going to have to investigate that brad nailer, I've just been using finishing nails and a hammer...
Get a good sawblade. Either for table saw or circ saw. 24 teeth is not enough. I've got a diablo 40-tooth for my table saw, and I love it. It was a super upgrade, ~$40. Smaller circular saw blades are impulse-buy cheap, even nice ones!
Always plan out your builds before you do anything, and see which pieces you can figure to be the same size. Cut them all at once, with the same guide settings. Sometimes this requires adjusting the blueprint - they aren't always optimized for this.
I've got a table saw, and I'm here to say that outfeed rollers are the best thing since sliced bread. Since I finally got one, now I wish I had 3...
Practice practice practice. I learn something with every build. Every time I see someone planning to buy $500 or more worth of drivers for their first project I think "Are you sure you wouldn't rather screw up a few cheaper projects first?" You can't tell that to someone with a fever to build, but a cheap FR project first will make your dream-build come out way nicer later.
Use a sawboard. Don't try to make one out of wood, though. I got an aluminum cutting guide from Home Depot for $20. The wooden one I tried to make had an ever-so-slight bow... not enough to easily see, just enough to screw things up!
Router + Flush trim bit. Oversize some bits of your cabinet, then trim them down after you've affixed them in place. Finding the way to use this bit of advice on your particular project is left as an exercise for the reader...
Just nail things into place. The builds I try to do clamp-only always slide around just a little. I'm going to have to investigate that brad nailer, I've just been using finishing nails and a hammer...
Get a good sawblade. Either for table saw or circ saw. 24 teeth is not enough. I've got a diablo 40-tooth for my table saw, and I love it. It was a super upgrade, ~$40. Smaller circular saw blades are impulse-buy cheap, even nice ones!
Always plan out your builds before you do anything, and see which pieces you can figure to be the same size. Cut them all at once, with the same guide settings. Sometimes this requires adjusting the blueprint - they aren't always optimized for this.
I've got a table saw, and I'm here to say that outfeed rollers are the best thing since sliced bread. Since I finally got one, now I wish I had 3...
Practice practice practice. I learn something with every build. Every time I see someone planning to buy $500 or more worth of drivers for their first project I think "Are you sure you wouldn't rather screw up a few cheaper projects first?" You can't tell that to someone with a fever to build, but a cheap FR project first will make your dream-build come out way nicer later.
i'm a professional woodworker, and i just have to say, for sure on the 40 tooth diablo and table saw safety. the table saw is quite an accident-prone tool, and the scary kind of accidents where body parts detach and fly about. another yeah for the flush trim router bit. and finally, for dog's sake, dry-clamp before you put any glue on!
Another professional (carpenter) here.
You will develop your own techniques, likes, dislikes &c. as you go along.
You will develop methods that work for you.
Safety cannot be over-emphasised!
Respect your tools, get comfortable using them, but never casual.
You can lose fingers, hands, whatever, quicker than one could ever imagine!!
Sorry if I've overstated the obvious, but I've seen it happen.
Have fun with it, make your mistakes, but be safe!!
Don
You will develop your own techniques, likes, dislikes &c. as you go along.
You will develop methods that work for you.
Safety cannot be over-emphasised!
Respect your tools, get comfortable using them, but never casual.
You can lose fingers, hands, whatever, quicker than one could ever imagine!!
Sorry if I've overstated the obvious, but I've seen it happen.
Have fun with it, make your mistakes, but be safe!!
Don
- Status
- Not open for further replies.