Thumbnail for initial mockup, my photoshop skill are severely lacking
Thumbnail for The girlfriend helping me pick plywood, she never got angry at me even once. I don't deserve her!
Thumbnail for The tweeter is kinda ugly in most of the pictures on the internet. It's actually pretty good looking in person, and the grill protecting the beryllium is probably a good idea!
Thumbnail for The SB23MFCL is stupidly heavy woofer. I was straining to hold it in this shot.
Thumbnail for After cutting all the braces and pieces using the same saw settings to get everything as perfect as possible. The pieces were carefully chosen to keep the grain continuous. The brace positions were marked on the side and rverything getting glued up and pin nailed to help keep things lined up.
Thumbnail for The vertical mid cab piece glued in.
Thumbnail for The mitered tops getting placed in, a careful balance of clamp pressure and weights.
Thumbnail for The continuous grain i mentioned earlier.
Thumbnail for The back glued in place. The veneer on this is mahogany so stained to match, but after rethinking it, I'm going to paint the back black. The rear will get flush cut with a router later
Thumbnail for The front baffle was tricky business. At this point I can't cut the woofer holes in the front part of the baffle, as I wouldn't have enough material for a router bit bearing when routing the profile for the hardwood edges. But I couldn't chamfer the rear of the driver hole if I cut the hole after it's all glue together. So here is the woofer being test fit in the rear baffle piece!
Thumbnail for The front piece of the front baffle! The holes drilled from the back to drop in the grill magnets, about 1mm back from the front surface! Additionally the slot is cut in both pieces of the front baffle. I just layed them in place and used a flush cut trim bit with a router to get them exact.
Thumbnail for Doweling glued in, to hold the grill magnets in place.
Thumbnail for The front and rear parts of the baffle glued together. Note the rear chamfer on the rear of the front baffle, to allow the woofer to breathe. I left extra material for the screws and to maintain some rigidity. It's all probably overkill but why not :)
Thumbnail for The tweeter and mid holes cutout using a router and jasper jig.
Thumbnail for Rear of the midrange driver cutout. With a 1.5inch front baffle and a small 5in driver, it becomes important to chamfer the rear of the cutout to allow the rear of the driver to breathe.
Thumbnail for The crossovers installed
Thumbnail for The dampening material installed
Thumbnail for The front baffle glued in place
Thumbnail for The woofer holes cutout with jasper jig, test fitting the woofer
Thumbnail for Test fitting the drivers, so close now
Thumbnail for Almost ready for the finish
Thumbnail for Hardwood edges glued in
Thumbnail for Edge glued in
Thumbnail for Famowood walnut woodfiller
Thumbnail for One coat natural danish oil, with dark walnut danish oil on the hardwood
Thumbnail for Close up of the incomplete 3/4
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Thumbnail for Clearcoat over sanded through shellac
Thumbnail for Delamination of the midgrade mahogany ply I used for the back
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