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Multi-Way Conventional loudspeakers with crossovers

Kappalite, B&C, Ciare, Heil Modular 3-Way build thread
Kappalite, B&C, Ciare, Heil Modular 3-Way build thread
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Old 11th July 2018, 05:10 AM   #1
Flaxxer is offline Flaxxer  United States
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Default Kappalite, B&C, Ciare, Heil Modular 3-Way build thread

Here we go. It all started innocent enough. With some panels cut to specific sizes …

[IMG]Click the image to open in full size.20180328_143120 by Cullen Graham, on Flickr[/IMG]

I wanted to design a floor standing pair of speakers, with incredible and effortless dynamics, with very realistic sounding instruments and voices. That "jump" factor, if you will. I wanted a fairly high efficiency, three way design, with the drivers mounted very close together. I wanted bass bins with a bolt in interchangeable port tuning system. I wanted the top cabinets to be extremely dead and resonant free, with the best diffraction possible within the design restraints. I'm looking for very powerful bass to 40 hz. And the highs need to sound like live percussion. (Almost forgot one of my main design goals; I want these to have ZERO mechanical vibrations, where they couple with the floor. Wait, what ?). These are made to ROCK!

I already have a pair of AMTs I love, in the small Heil monopoles. I did NOT want to be a lemming, lol. I did not want to use the Faital Pro line for mids or lows. I had been really trying to decide between the B&C 6MDM38 mids, and the Ciare NDK-6 1.5 mids. Then I realized they will countersink almost perfectly in the exact same routed hole for the front baffle! I get to have a DSP setting for both midrange drivers. I can switch them out if I want to! Modular design goals.
Wait, DSP ? Yes. These will be fully active, with onboard amplifiers. These should be DYNAMIC! More tomorrow.

[IMG]Click the image to open in full size.20180401_133855 by Cullen Graham, on Flickr[/IMG]

[IMG]Click the image to open in full size.20180403_125043 by Cullen Graham, on Flickr[/IMG]

[IMG]Click the image to open in full size.20180526_201518(0) by Cullen Graham, on Flickr[/IMG]

[IMG]Click the image to open in full size.20180526_201532 by Cullen Graham, on Flickr[/IMG]

[IMG]Click the image to open in full size.20180609_120116 by Cullen Graham, on Flickr[/IMG]

[IMG]Click the image to open in full size.20180610_115715 by Cullen Graham, on Flickr[/IMG]

[IMG]Click the image to open in full size.20180610_115728(0) by Cullen Graham, on Flickr[/IMG]

Last edited by Flaxxer; 14th July 2018 at 01:43 AM.
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Old 11th July 2018, 08:16 PM   #2
Flaxxer is offline Flaxxer  United States
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I started on the top cabinets. I had never worked with a tiny .303 air volume before, and I had extra room in the mid/high cabs. I wanted very solid and dead top cabinets. So I decided to fill the void between the outer enclosure, and the two smaller enclosures inside with fine sand. Someone kindly modeled my 6" roundover top cabinets, and it showed super flat response from very little baffle diffraction. Each top enclosure has two hollow, 6" half round sides on it. I'm also filling these half rounds with fine sand. These should be VERY non resonant!


[IMG]Click the image to open in full size.20180617_184954 by Cullen Graham, on Flickr[/IMG]

[IMG]Click the image to open in full size.20180617_185153 by Cullen Graham, on Flickr[/IMG]

[IMG]Click the image to open in full size.20180628_102959 by Cullen Graham, on Flickr[/IMG]
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Old 11th July 2018, 09:45 PM   #3
Flaxxer is offline Flaxxer  United States
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And after making sawdust for a while, this happened...


[IMG]Click the image to open in full size.20180701_153430 by Cullen Graham, on Flickr[/IMG]


Next I glued the strips on the cabinet sides, which are guides for the half rounds. After that, you can see I traced each half round bottom, and cut out the wood half rounds, and glued them on. These made the bottoms for the sand filling.


[IMG]Click the image to open in full size.20180703_103126 by Cullen Graham, on Flickr[/IMG]


Woah ! A woofer sneak peek!

[IMG]Click the image to open in full size.20180703_171049 by Cullen Graham, on Flickr[/IMG]

[IMG]Click the image to open in full size.20180703_172658 by Cullen Graham, on Flickr[/IMG]

[IMG]Click the image to open in full size.20180705_140221 by Cullen Graham, on Flickr[/IMG]
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Old 11th July 2018, 09:54 PM   #4
ErnieM is offline ErnieM  United States
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Looking good. I have a sense that the Ciare mid will be the higher quality solution. Ciare products I've used have been exceptional.
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Old 11th July 2018, 10:03 PM   #5
Flaxxer is offline Flaxxer  United States
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And this is the easy way to make half rounds on speakers. Quarter rounds of ANY size, can be done the exact same way, for straight side walls.


[IMG]Click the image to open in full size.20180706_122134 by Cullen Graham, on Flickr[/IMG]

These voids can be left empty, or filled with anything you want to try! I like sand the best personally.

Click the image to open in full size.20180706_122121 by Cullen Graham, on Flickr


Once you undo the tape, and trim any excess adhesives away, you get this kind of thing happening .


[IMG]Click the image to open in full size.20180701_163458 by Cullen Graham, on Flickr[/IMG]

[IMG]Click the image to open in full size.20180701_163454 by Cullen Graham, on Flickr[/IMG]


[IMG]Click the image to open in full size.20180701_163440 by Cullen Graham, on Flickr[/IMG]

[IMG]Click the image to open in full size.20180701_163515 by Cullen Graham, on Flickr[/IMG]


Nest I began the bracing, which can't be completed until MY slot load, vs port load set up is decided. More on that later.


[IMG]Click the image to open in full size.20180707_154324 by Cullen Graham, on Flickr[/IMG]

[IMG]Click the image to open in full size.20180707_140935 by Cullen Graham, on Flickr[/IMG]


Next I made a way to have different types of bass bin tuning options Modular One


[IMG]Click the image to open in full size.20180708_105938 by Cullen Graham, on Flickr[/IMG]

[IMG]Click the image to open in full size.20180708_105948 by Cullen Graham, on Flickr[/IMG]


Which leaves me just about here .


[IMG]Click the image to open in full size.20180708_110101 by Cullen Graham, on Flickr[/IMG]
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Old 11th July 2018, 10:12 PM   #6
Flaxxer is offline Flaxxer  United States
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Quote:
Originally Posted by ErnieM View Post
Looking good. I have a sense that the Ciare mid will be the higher quality solution. Ciare products I've used have been exceptional.
I will know for sure in the future. One pair will find a new home, lol. Amazing to have a drop in comparison solution like this. I was ready to do a dance! LOL

There will be a pair of Aurum Cantus AST-25120s in the future. But at $600 for the pair, that will be a ways in the future. I have 4 more items to purchase first, to complete my build. The tweeters will be a luxury. To be honest, I am truly wondering if they can best the Heils over 3000hz. BUT, they can be crossed over as low as 1200 with ease. But then I would wonder why I spent a lot on a mid driver that only plays from 300hz to 1200hz LOL
Having said all of the above, stripping the front finish material from the top cabinets, in order to FILL in the holes cut for the Heils, to then re-cut holes for the AST-25120s is going to be NOT as easy as the drop in mids !
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Old 12th July 2018, 04:27 AM   #7
Flaxxer is offline Flaxxer  United States
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So my design goals were: I wanted a fairly high efficiency, three way design, with the drivers mounted very close together. I wanted bass bins with a bolt in interchangeable port tuning system. I wanted the top cabinets to be extremely dead and resonant free, with the best diffraction possible within the design restraints.

Well my drivers are definitely close enough together, lol. And the efficiency should be right around 94-95db. The top bins are going to be DEAD, and very heavy/solid. The bass bins are meeting criteria. So far, so good.


I am going to spread Bondo smooth on the roundovers on the top cabinets, and finish them with .. ha ha! Will have to stay tuned for that part. Then I add the internal wiring, fill them with sand, and seal the tops. I will add the top cap, and the top cabs will be finished.

I will be adding the bass bins internal lining, and seal the first one up completely. Then it will be time for the first port tuning! These could be playing tomorrow, if I had enough time.
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Old 12th July 2018, 07:24 AM   #8
RobWells is offline RobWells  United Kingdom
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Nice project Clever idea on the rounded sides. Did you freehand route the recess for the mid speaker or use a jig ?

Rob.
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Old 12th July 2018, 11:23 AM   #9
ewollowe is offline ewollowe  Australia
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So jealous of the half rounds. Nice project.
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Old 12th July 2018, 04:38 PM   #10
Flaxxer is offline Flaxxer  United States
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Quote:
Originally Posted by RobWells View Post
Nice project Clever idea on the rounded sides. Did you freehand route the recess for the mid speaker or use a jig ?

Rob.
Ha ha ha! I was waiting on this, Rob. LOL I tried making a couple of jigs, but somehow each one I messed up before it was finished. So everything you see was freehand routed, with a 1/2 hp router, and a Dremel tool, without any guides. All freehand. Thus the mistakes I will be trimming with Bondo, before I finish them.
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