The Bully Build Begins

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robwm

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The Bully Build Begins
« on: 7 Mar 2025, 02:18 pm »
Hi,

I received my Bully flatpack yesterday. Let the fun begin! Any ideas on order of assembly?





-Rob
« Last Edit: 10 Mar 2025, 07:30 pm by robwm »

NIGHTFALL1970

Re: The Bully Build Begins
« Reply #1 on: 7 Mar 2025, 03:31 pm »
Best of luck 🍀!

Peter J

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Re: The Bully Build Begins
« Reply #2 on: 7 Mar 2025, 03:38 pm »
Hi,

I received my Bully flatpack yesterday. Let the fun begin! Any ideas on order of assembly?


-Rob

I've never seen one of these, so my assembly suggestions are as follows:

1. Remove plastic
2. spread parts out so we can see what we're up against
3.
4.
5.
6.

robwm

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Re: The Bully Build Begins
« Reply #3 on: 7 Mar 2025, 03:40 pm »
Looks like 18 parts per speaker with no instructions. What could go wrong?  lol




robwm

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Re: The Bully Build Begins
« Reply #4 on: 7 Mar 2025, 04:08 pm »
The cuts are very nice and clean. I think the next move I take will be to attempt to match the parts to the cabinet plans to understand how it goes together. Try out some dry fitting.

By the way, I'm planning to write an assembly tutorial for my build of this speaker. I have a fairly unique idea in mind. The tutorial is about 4 pages so far with no pictures (many will be added).

Writing this helps me to think out the process clearly.

Peter J

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Re: The Bully Build Begins
« Reply #5 on: 7 Mar 2025, 05:04 pm »
I'm guessing at some of this, but for sure dry assemble at least once and develop a game plan. People sometimes laugh at my clamp collection, but I can tell you there are times when I've used more than many think are necessary. Beg, borrow, steal what you need. Well, don't steal but you get the picture.

Use slow setting glue, I use Titebond Extend almost exclusively now. No downside that I've found.

There may be a way to do sub-assemblies but I am mostly not in that camp as it can produce surprising and unwanted mis-alignments. Perhaps some of the interior parts can use sides and backs as place holders while saving the glue up of those guide pieces till later.

For me, having a flat, hard and stable surface that's at a comfortable working height is crucial, meaning not the floor. But I'm old. Sawhorses and plywood will suffice, but those rickety fold up tables are almost more hassle than they're worth.

Have everything you need close at hand. You don't want to be searching in your garage or making trips to the store in the middle of a glue-up.

If you can't visualize the process start to finish, I would suggest you're not ready for glue-up. "Figuring it out when I get there" is folly, especially with so many pieces. There's enough to execute without throwing curve balls to yourself.

If you were close, I'd offer to help.

robwm

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Re: The Bully Build Begins
« Reply #6 on: 7 Mar 2025, 05:23 pm »
That seems like solid advice to me. Until it stops feeling overwhelming, no glue should be applied.

What are your thoughts about using #8 Spax wood screws in addition to glue? Not many, just enough for extra strength.

Peter J

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Re: The Bully Build Begins
« Reply #7 on: 7 Mar 2025, 05:45 pm »
That seems like solid advice to me. Until it stops feeling overwhelming, no glue should be applied.

What are your thoughts about using #8 Spax wood screws in addition to glue? Not many, just enough for extra strength.

My beef with screws into edges of MDF is they tend to split the edge, which tends to bulge the adjacent flat surfaces. They can be useful as clamping devices, but I'd pre-drill pilots and, more often than not, remove afterwards. I would argue that if an assembly like this is relying on screws for strength, there's something wrong. In such a structure, they would only provide additional strength in sheer. How much sheering force in speaker cabinets? If they're being asked to withstand say, hurricane force wind or being dropped out of a helo, I think other things would be more pressing.

Tyson

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Re: The Bully Build Begins
« Reply #8 on: 7 Mar 2025, 05:48 pm »
Avoid screws.  The glue will form a bond stronger than the wood around it, so there's no need for screws (or nails).

robwm

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Re: The Bully Build Begins
« Reply #9 on: 7 Mar 2025, 05:52 pm »
Ok, a friend of mine tried screws and he experienced some bulging from the screws. Screws came to mind when i was looking at the second baffle. They could help secure the piece and maybe help with alignment.

I want the speakers to be able to survive a car crash if I am transporting them for some reason.  :lol:

Peter J

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Re: The Bully Build Begins
« Reply #10 on: 7 Mar 2025, 05:59 pm »
Ok, a friend of mine tried screws and he experienced some bulging from the screws. Screws came to mind when i was looking at the second baffle. They could help secure the piece and maybe help with alignment.

I want the speakers to be able to survive a car crash if I am transporting them for some reason.  :lol:

Be sure your car has lots of airbags and don't forget to belt them in.

nlitworld

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Re: The Bully Build Begins
« Reply #11 on: 7 Mar 2025, 06:18 pm »
Be sure your car has lots of airbags and don't forget to belt them in.
Lol. Peter, I love your dad jokes.

Another handy tip for my speakers was threaded inserts and machine screws for mounting the drivers. Definitely makes it easy if ever getting back into the speaker to adjust polyfill or tweak crossover.

Excited to see how these come together.

robwm

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Re: The Bully Build Begins
« Reply #12 on: 7 Mar 2025, 06:27 pm »
After looking over the wood, I'd say some light sanding for all glue joints is the first step. You can see a few markings from power tools. Along with some dry fitting to see where the glue lines are on pieces where it's not so obvious.

robwm

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Re: The Bully Build Begins
« Reply #13 on: 10 Mar 2025, 03:23 pm »
So, I did some very light sanding to level off the cuts. After that, I performed a dry fit of the right speaker (I'm working on only the right speaker). Part "H" is not installed to show the rest of the assembly.




robwm

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Re: The Bully Build Begins
« Reply #14 on: 10 Mar 2025, 03:25 pm »
As far as I can tell, the second baffle needs to be glued first. I don't see any way it could be done at a later stage.




« Last Edit: 10 Mar 2025, 07:19 pm by robwm »

robwm

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Re: The Bully Build Begins
« Reply #15 on: 10 Mar 2025, 03:29 pm »
Next step looks like the two parts "B" need to be glued to the right-side panel (as looking at the front of the speaker). It seems most logical to build most of this on the right-side panel. I glued one part "G" also.




« Last Edit: 10 Mar 2025, 07:18 pm by robwm »

robwm

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Re: The Bully Build Begins
« Reply #16 on: 10 Mar 2025, 07:13 pm »
The next step looks like you should glue part D to part G. Use a dry assembly to hold it position while the glue cures.









Peter J

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Re: The Bully Build Begins
« Reply #17 on: 10 Mar 2025, 07:43 pm »
Rob, to make it a little less daunting, I think you could glue up the center assembly using sides and back as place holders. This would make final assembly somewhat easier.

FWIW, machine marks on panel edges shouldn't affect gluing but sanding them off probably won't have an effect either. If dados are snug, I often use a sanding block to ever-so-slightly bevel panel edges so that they kind of funnel into place. It won't affect assembly strength and also gives a little relief area for excess glue which decreases needed clamping force a bit.

Seems you've got a handle on it. Not rushing will reward you at some point, but then I plod through things so take that FWIW.

robwm

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Re: The Bully Build Begins
« Reply #18 on: 10 Mar 2025, 07:54 pm »
I'm just taking it slow as I have heard many people say in these forums. It might not be the best or efficient approach, but I feel like the stages I am using are safe, so I'll roll with it. Maybe I can speed things up on the left speaker after making it through one. No chance I can afford another kit if I mess this one up. I suppose I could use the drivers for fruit bowls?

My strategy is to essentially to avoid too many glue lines at once. Spend some time thinking through what might happen before even trying. Make sure all clamping is in one direction. I can't really do any overlapping of clamps with the type I am using.

As far as the sanding goes, I barely even had to touch the wood to smooth it out a little. I couldn't help it. Call it the OCD in me. lol

I never attempted anything even close to this in my life, but I have seen enough youtube videos to supervise a woodshop.  :lol:

robwm

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Re: The Bully Build Begins
« Reply #19 on: 20 Mar 2025, 02:54 pm »
I have gotten the right speaker together except for the front and back. The left speaker will reach this stage by Sunday. I'm a bit behind on posting pictures so I'll be trying to get that caught up this weekend. I think from here I should start getting the insulation installed while access is very easy.

It is also time to start building the crossover. I was only provided one board for two crossovers, and it is way too small for the Bully crossover. I bought a 1/4" x 2ft x 4ft piece of MDF and I will cut custom pieces for the crossover. I plan to build it similarly to how Danny demonstrates in his videos.

I also bought a 3/4" x 2ft x 4ft MDF to mockup some pieces for router practice. I don't want my first router cut to be on the speaker cabinets.