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I'm Feeling lucky
initial mockup, my photoshop skill are severely lacking
The girlfriend helping me pick plywood, she never got angry at me even once. I don't deserve her!
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!
The SB23MFCL is stupidly heavy woofer. I was straining to hold it in this shot.
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.
The vertical mid cab piece glued in.
The mitered tops getting placed in, a careful balance of clamp pressure and weights.
The continuous grain i mentioned earlier.
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
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!
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.
Doweling glued in, to hold the grill magnets in place.
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 :)
The tweeter and mid holes cutout using a router and jasper jig.
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.
The crossovers installed
The dampening material installed
The front baffle glued in place
The woofer holes cutout with jasper jig, test fitting the woofer
Test fitting the drivers, so close now
Almost ready for the finish
Hardwood edges glued in
Edge glued in
Famowood walnut woodfiller
One coat natural danish oil, with dark walnut danish oil on the hardwood
Close up of the incomplete 3/4" roundover profile
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Clearcoat over sanded through shellac
Delamination of the midgrade mahogany ply I used for the back
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