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Revelation: Speaker Enclosures FINISHED (pg. 2)

post #1 of 13
Thread Starter 
I've been wanting to do a scratch built case for a long time... wood is a material that always spoke to me because of it's limitless potential. Even though it is the most organic material available to builders, it allows those working with it the opportunity create really angular, inorganic shapes. That's what I'm trying to achieve with this build.

Although I will eventually make a case in the same style, I decided to start with something much simpler - speaker enclosures. The drivers and crossover are from parts express' br-1s kit, which I bought on sale for 100 dollars. The entire enclosure will be made by me.
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post #2 of 13
Thread Starter 
Day 1 - Chipboard Prototype:

In order to get comfortable with the actual construction of these enclosures, and to get a feel for the necessary dimensions, I decided to start with chipboard. It's much cheaper and easier to work with than the birch ply I picked for the final version.

The components also came in today, so let's get a look at those:

Woofer:


Tweeter:


The unsuspecting, virgin chipboard:


Drawing the face with respect to the dimensions of the components:


Cut out:


Coming Together, but wayyy more angular than I wanted:


Starting to get a sense of how large these are going to be once they're made with 1/2" birch ply:


At this point I had learned what I wanted to and there was no need to finish the model:


I decided that the finished version is going to be much tighter and squarer, with less extreme angles than this. But it's much better to learn that with ten dollars worth of chipboard than seventy dollars worth of wood.

I called it a day at this point and decided I would start in on the wood tomorrow with my new design considerations in mind
Edited by ZombieAttack27 - 1/19/13 at 2:50pm
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post #3 of 13
Thread Starter 
Sorry about the image quality in this update, I didn't want to bring my camera into the shop so I used my phone camera... I'm at school but thankfully we have some of the best facilities / techs in the country so they'll be here to give me advice every step of the way. The downside is that during this part of the year, woodshops are only open for a couple hours a day on the weekends. Since I planned most of this build out in chip board I won't have to do too much measuring / planning when I'm there, but the current schedule will slow my production down a bit.

Drawing the plans for the first layer of the face plate onto my fresh sheet of birch ply. I'm already changing the proportions and placement of things since I wasn't completely satisfied with the model


First one is roughly cut out... now I need to define the shapes that will eventually become the feet of these speakers


Looking pretty good. We didn't have hole saws big enough for my drivers so I got close with the scroll saw then perfected it with a spindle sander. I'm really happy with the holes since they were basically done by hand.


There will be a piece behind both of these with a larger perimeter, but smaller holes to create a lip for the drivers to sit on.

Edited by ZombieAttack27 - 1/21/13 at 9:47am
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post #4 of 13
Awesome project! I'll be following along.
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post #5 of 13
I just built some speaker cabinets in nov and dec. using speakers from madisound, and some x-overs from parts express, 3-way Eminence ones, they are HUGE! Premium white oak stock, 3 ways, 8" woofer, 5.5" mid, and 1" tweet (that resembles yours ALOT) Red oak stain, and DAYS of labor. Good luck on your project, and do everything RIGHT. Do NOT shortcut ANYTHING. I soldered EVERY connection, used twisted pair oxygen free copper 16 ga. wire, went all out. Have fun!

Of course my design was a generic box shape, no fancy curves and such, but I'm not an experienced wood crafter. I do car audio boxes too, so my preference and experience is standard shape boxes.


Edited by SwishaMane - 1/20/13 at 8:44am
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post #6 of 13
Thread Starter 
Thanks for the encouragement guys... I have two days worth of pictures, just need to update the posts. I bet those sound awesome
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post #7 of 13
Thread Starter 
Day 2 posted above... day three to come later today
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post #8 of 13
Nice work! I actually really like the early, angular mockup. You don't see those shapes every day.

Am I right in assuming you'll build the computer components into one of the speaker enclosures?
 
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post #9 of 13
Great to see someone doing something a little different!

Best of luck with your speakers, looking great so far!
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post #10 of 13
Thread Starter 
Quote:
Originally Posted by She loved E View Post

Nice work! I actually really like the early, angular mockup. You don't see those shapes every day.

Am I right in assuming you'll build the computer components into one of the speaker enclosures?

Thanks, the final will look verryy similar to the chipboard mockup... even identical to the unsuspecting eye, I just want to tighten some things up proportionally and get them closer to the golden ratio (1:1.618). I liked the look to since it was the winner or five or so sketches, it can just be difficult bringing a 2d idea into our 3d reality sometimes.

I don't think I would be able to fit a computer inside the speakers, and even if I could I'm not sure I would want to since the interior of the speaker has a huge impact on the sound. The idea is to make these first, then make a matching, full-tower sized case out of the same materials, with the same style.... completely watercooled
Quote:
Originally Posted by trippinonprozac View Post

Great to see someone doing something a little different!

Best of luck with your speakers, looking great so far!

I appreciate it! I figured that at the end of all this work, I might as well have something one of a kind. The downside is that the base of knowledge for speaker enclosures online is all based around rectangular, traditional housings and the acoustics of this thing are going to be a huge gamble. I've gathered that the safest bet is to use cheap, quality components (check), keep the whole thing sealed instead of ported, and fill it almost to the brim with polyester pillow stuffing. The good news is that nobody on OCN will be there to listen to them, so if they look good in pictures I should be set wink.gif

Day 3: Little Progress and Stain Testing

Today I just tested out the stains I bought on some pieces of scrap. I want the build to be two tone, so I went with both chestnut and natural stains. I'm planning on using matte urethane finish on everything, but the point of this exercise was to determine if that's a good idea or not. Unfortunately, this is plywood after all, and it doesn't take stain well at ALL. I'm extremely unhappy with the results and I'm going to have to keep trying new things until that changes.



In more bad news, the woodshop surprised me with weird hours so I wasn't even able to cut anything out... I drew the outlines for the second halves of the face plates though.



I also test fit the components into the finished pieces and I won't put pictures up until I'm farther along... but I'm REALLY happy with the way that they look. The way they sound remains to be seen, but for now they look pretty sweet.
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