Jared called and asked if we could build subwoofer cabinets for a pair of some 24" drivers he was having built. We had done 18" subs in the past and so it didn't seem like much of an issue.
About two months later, a truck delivered a pallet with two HUGE cartons. After opening one of the cartons, I realized we had an issue. This was going to be a MASSIVE task...far in excess of what I had imagined. But since we committed to building them, we went to work.
The first task was to design all the internal bracing to accommodate the drivers and plate amp. It was a bit more complicated than usual since we had to support the driver magnet. If we failed to do that, if the truck delivering them hit a bump, it would probably rip the magnet right off the driver frame (the magnets were massive).
Once we got everything to dry fit perfectly, we assembled the cabinets.
We then finished the cabinets and they were ready for final assembly.
This was no simple task as each driver weighed at least 150 pounds. So much care had to be taken to align the driver perfectly before lowering it into place since it would be almost impossible to re-align it afterwards.
So how do you lower a massive driver into place? Well, we built a large post that was fed up through the amp cutout to support the driver magnet. A pallet jack held the driver slightly above the driver cutout. Then, when the driver was properly aligned, we slowly lowered the pallet jack allowing the driver to drop into place in the cabinet.
Once the driver was in place, we finished the assembly of the braces that locked the driver magnet securely in place.
This was the final result. Mary never likes to have her picture taken, but we needed a body in the shot to gain some perspective. She was nice enough to oblige.
We estimated that each of the subs weighed somewhere between 350 - 400 pounds. I have no idea how Jared moved them into his home theater, but he reported that after the set-up was complete, they were making serious bass flat to 5Hz.
Happy listening (and feeling) Jared...