Just want to pass the construction idea past people. To make the bass and treble enclosures, takes the length of carboard tube (bass is 50cm long, mid 47, conveniently) and, using a ply jig, place 4 M6 studs along the outside length, with M6 internally threaded adaptors welded on the end.
Fibreglass the structure, keeping it as round as possible despite the studs.
Then wrap with sound deadening material, again keeping as round possible.
Insert assembly into PV pipe with an overhang each end and fill airgap with builder's expanding foam.
Make two two part bungs, one part fitting inside the PVC, one inside the cardboard tube. One bung will be the baffle, one the back. Route the baffle end so the allen bolts used to attach the ends to the rods are flush. It may be necessary to turn up the bolts for sufficient surface area. This can be done.
Make a rubber gasket.
Fit connectors, fill with foam etc and screw ends onto tube and driver onto baffle.
Add bungs, one with an air conditioning valve in the part that will be cut out for the driver.
Trim pipe.
Run air con pump to check they are airtight.
If so, fit foam, connectors, mount driver off centre in baffle, and assemble.
These can easily be taken apart for further tweaking.
If not, seal firmly and curse, because in future access is only via the driver hole.
Costs to this point are minimal, so the methods can be refined and the process repeated until all four enclosure are made.
Sound reasonable?
Fibreglass the structure, keeping it as round as possible despite the studs.
Then wrap with sound deadening material, again keeping as round possible.
Insert assembly into PV pipe with an overhang each end and fill airgap with builder's expanding foam.
Make two two part bungs, one part fitting inside the PVC, one inside the cardboard tube. One bung will be the baffle, one the back. Route the baffle end so the allen bolts used to attach the ends to the rods are flush. It may be necessary to turn up the bolts for sufficient surface area. This can be done.
Make a rubber gasket.
Fit connectors, fill with foam etc and screw ends onto tube and driver onto baffle.
Add bungs, one with an air conditioning valve in the part that will be cut out for the driver.
Trim pipe.
Run air con pump to check they are airtight.
If so, fit foam, connectors, mount driver off centre in baffle, and assemble.
These can easily be taken apart for further tweaking.
If not, seal firmly and curse, because in future access is only via the driver hole.
Costs to this point are minimal, so the methods can be refined and the process repeated until all four enclosure are made.
Sound reasonable?
