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Multi-Way Conventional loudspeakers with crossovers

New active 3-Way, Hypex and SB
New active 3-Way, Hypex and SB
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Old 14th April 2020, 05:38 PM   #1
hifijim is offline hifijim  United States
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Default New active 3-Way, Hypex and SB

I just completed a new active 3 way system. I used a pair of Hypex Fusion FA253 amps.

Woofers are SBA SB34NRX75-6, in a 70 liter sealed box. The ideal sealed box for this woofer is about 110 liters, so I used a Linkwitz transform to adjust the response. boost starts at 38 Hz, and by 26 Hz I have 6 db of boost. The crossover to the mid is currently 200 Hz LR4.

The mids are SBA SB17CAC35-4, an aluminum/ceramic 6 inch driver. The box is 10 liters sealed. The cabinets have 1.5 inch roundover on the sides, and a 30 / 60 degree dual bevel along the top.

The tweeters are SBA SB26CDC-C000-4, an aluminum/ceramic dome. Crossover from the mid is 2 kHz LR4.

The Hypex DSP features are powerful, and I was able to equalize all the drivers flat through the passband and stopband. I applied digital delay to the mid and tweeter to bring all the drivers into the same plane as the woofer. The Hypex amp is mounted in the speaker stand.

I am not done fine tuning the filters, but I am going to listen to them for a few weeks before I make any further adjustments. They sound pretty amazing right now.

Thanks for everyone who conversed with me over the last 7 months. I learned a lot, and this project would not have been successful without the DiyAudio community.
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Old 14th April 2020, 05:45 PM   #2
TimbreAudio is offline TimbreAudio  United Kingdom
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Great work!
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Old 14th April 2020, 08:21 PM   #3
manninen is offline manninen  Finland
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yeah, especially sub boxes looks good
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Old 14th April 2020, 09:12 PM   #4
Dave Bullet is offline Dave Bullet  New Zealand
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They look great! I recall you posted on my Cathedrals thread. I'd be interested if you could post your transfer functions if you have these available please.
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Old 14th April 2020, 09:25 PM   #5
hifijim is offline hifijim  United States
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Some construction pics:

The satellites are 3/4 inch baltic birch plywood, with the baffle being a composite of 3/4 solid african mohogany and 3/4 BB plywood.

In the 4th photo you can see the bracing scheme for the satellites. On the left box you are looking at the rear, on the right box you are looking at the front. The rear baffle is inset, and the front baffle overlays the box.

The next photo shows the primary bracing for the woofer boxes. Upper and lower bulkheads (some call them holey braces) and a central solid bulkhead shaped around the woofer magnet.

The woofer boxes are 3/4 inch baltic birch ply, front baffle is a double layer.

The 7th photo shows the secondary bracing for the tops and bottoms.
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Old 14th April 2020, 09:53 PM   #6
hifijim is offline hifijim  United States
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This pic shows the end caps (top and bottom) being glued onto the woofer cabinet. Most of the adhesive I used was Titebond III (a PVA wood glue), but for the tops and bottoms I used West Systems epoxy. I have a lot of epoxy experience because I have refurbished an old boat. Epoxy mixed with colloidal silica and microfibers has excellent gap-filling properties, and I had some gaps in the top and bottom fit-up.

I also used epoxy to laminate the satellite baffle together. The solid mahogany and the birch plywood were epoxied together, and then later epoxy was used to attach the front baffle to the box carcass.

Also in the pic you can see some dark wood plugs where I used screws. I had a spare walnut dowel from another furniture project, and there are other birch and maple plugs which you can not see very well. Although I was able to get a close fit between the bracing and the cabinet walls (close enough for normal furniture and cabinet making), I knew that speaker cabinet stiffness would depend on an exact fit. In some cases I used shims to fill any small gaps, but most of the time the fit was close enough I could just use counterbored screws to pull the cabinet walls tight against the bracing.

The satellites are veneered with Brazilian mahogany, and the front baffle is African mahogany. Before varnish, they were closer in color to each other, but after varnish it is more like a two-toned finish. The woofer cabinets are walnut veneer. The speaker stands are veneered in maple.

This was my first time working with veneer. All my previous furniture projects have been in solid wood. I used PSA (Pressure Sensitive Adhesive) backed veneer, also known as peel-and-stick. Before applying the veneer, I used a belt sander to make all the butt edges smooth and flush with the panels. The veneer vendor advised me to put down a coat of finish on the raw plywood before veneering, he said that PSA sometimes did not adhere well to raw wood. He advised a coat of water based polyurethane. However, I did some experimenting, and found that as long as the plywood was smooth and dust free, the PSA adhered very well. After belt sanding the cabinets, I used a cabinet scraper to leave a smooth burnished surface, then I vacuumed the surface.
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Last edited by hifijim; 14th April 2020 at 10:02 PM.
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Old 14th April 2020, 10:07 PM   #7
troystg is offline troystg  United States
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Very nice!
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Old 14th April 2020, 10:08 PM   #8
hifijim is offline hifijim  United States
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Quote:
yeah, especially sub boxes looks good
Thanks... my wife was very pleased with how it turned out. Here is the other sub

I applied 3 coats of General Finishes Arm-R-Seal (gloss) using a 2 inch wide china bristle brush. After the first coat I sanded with 220, and after the second coat I sanded with 320.
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Old 14th April 2020, 10:11 PM   #9
hifijim is offline hifijim  United States
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Quote:
I recall you posted on my Cathedrals thread. I'd be interested if you could post your transfer functions if you have these available please.
Dave - do you mean the filter and EQ settings I used in the HFD software? I am not sure how to export them and display them... I could take screen shot of the HFD filter design window, but that does not give you all the filter information for each filter. Maybe I am missing something?

jim
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Old 14th April 2020, 10:27 PM   #10
hifijim is offline hifijim  United States
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Here is the tweeter response. First is the fully eq'd response without the crossover filter, and the second is the response with the filter.

Notice the ripple above 5k? I now think that is a reflection/diffraction from my hacked up microphone stand. I had the mic several inches from a hard reflecting surface. I had thought a small 5 inch by 6 inch plywood shelf would not affect the response... well I think I was wrong.
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File Type: pdf HF-R-wEQ0411.pdf (137.8 KB, 219 views)
File Type: pdf HF-R-wEQ-wXovr-0411.pdf (137.3 KB, 138 views)
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