DIY 3-way horn speakers

Wardsweb · « **on:** 17 Nov 2009, 01:05 pm »

I thought I would post on my DIY horns. I actually started these around January 2006. Once they were built and dialed in, I didn't want to take them back apart for veneer because I was enjoying listening to them. Well having to take the speakers out of my living room for a new floor was the perfect time to actually finish the job.

To start, here is a picture of some of the internal construction; part MDF and part Baltic birch.

Wardsweb · « **Reply #1 on:** 17 Nov 2009, 01:06 pm »

The sides are four layers of kerf MDF that I filled with glass microbeads used in bead blasting.

Wardsweb · « **Reply #2 on:** 17 Nov 2009, 01:06 pm »

Here they are with the raw Sapele Pommele veneer on.

Wardsweb · « **Reply #3 on:** 17 Nov 2009, 01:07 pm »

This is with three coats of DEFT gloss lacquer finish. I will apply a few more coats, sand, polish and buff for a piano gloss.

mgalusha · « **Reply #4 on:** 17 Nov 2009, 04:32 pm »

I believe I now have to clean the drool off my desk.

Really really nice.

poseidonsvoice · « **Reply #5 on:** 17 Nov 2009, 10:35 pm »

My new subs are being finished in this same veneer. Its just vibrant with a few coats of polyurethane.

Great stuff! Always appreciated your amp builds as well!

Anand.

Hebrew Hammer · « **Reply #6 on:** 18 Nov 2009, 01:09 am »

very...very nice!!!!

Pez · « **Reply #7 on:** 18 Nov 2009, 01:58 am »

Excellent stuff! Can't wait to see the final product.

Wardsweb · « **Reply #8 on:** 18 Nov 2009, 03:12 am »

Yes I will be sure to post the finished speakers in my system. I have scheduled some machine time on Thursday to turn the feet from 3" billet bar stock. I though the feet should be hefty to go along with these 300 pound speakers.

JoshK · « **Reply #9 on:** 18 Nov 2009, 03:14 am »

I think I asked on diyA, but I didn't read if you responded. What horn are you using in the empty space?

Wardsweb · « **Reply #10 on:** 18 Nov 2009, 03:48 am »

Quote from: JoshK on 18 Nov 2009, 03:14 am

I think I asked on diyA, but I didn't read if you responded. What horn are you using in the empty space?

The drivers are JBL 2235H woofers, Altec 802-8G drivers mounted to Altec 511B horns and JBL 077 slot tweeters.

Wardsweb · « **Reply #11 on:** 21 Nov 2009, 05:06 pm »

I'm also turning some 3" x 2" billet feet for them.

JoshK · « **Reply #12 on:** 21 Nov 2009, 08:31 pm »

Excellent. These are going to be heirlooms!

BTW, what machine do you use to turn aluminum? Is it a milling machine?

Wardsweb · « **Reply #13 on:** 22 Nov 2009, 12:09 am »

Quote from: JoshK on 21 Nov 2009, 08:31 pm

Excellent. These are going to be heirlooms!

BTW, what machine do you use to turn aluminum? Is it a milling machine?

It is a metal lathe. Turns like wood but with different tools.

gonefishin · « **Reply #14 on:** 22 Nov 2009, 04:59 am »

Hi Wards. The speakers are gorgeous! That finish is absolutely to die for...

...nice job!

dan

Wardsweb · « **Reply #15 on:** 25 Nov 2009, 03:47 am »

I love the figuring in the wood and the depth many coats of lacquer gives. Even the feet turned out really nice and polished well. I'm almost done.

Rocket_Ronny · « **Reply #16 on:** 25 Nov 2009, 04:39 am »

Awesome job Wards. Fun to watch it take shape.

Can you explain the bead filling of the mdf kerfs? Are they heated in some way and pressed into the kerfs? Then when they cool become hard. Just a guess.

What drivers, and crossover, are you using?

Rocket_Ronny

Wardsweb · « **Reply #17 on:** 25 Nov 2009, 04:53 am »

Quote from: Rocket_Ronny on 25 Nov 2009, 04:39 am

Awesome job Wards. Fun to watch it take shape.

Can you explain the bead filling of the mdf kerfs? Are they heated in some way and pressed into the kerfs? Then when they cool become hard. Just a guess.

What drivers, and crossover, are you using?

Rocket_Ronny

The beads are finer than sand and pour like water. You use them right out of the bag. I bought a 50 pound bag and used about half. No heating or anything. Just pour in and epoxy the top.

The drivers are JBL 2235H woofers, Altec 802-8G drivers mounted to Altec 511B horns and JBL 077 slot tweeters.

Wardsweb · « **Reply #18 on:** 29 Nov 2009, 12:46 am »

FINALLY they are back playing in my living room. I was going to leave the grills off but you will notice the left dust cap is dented. That is compliments of our 6 year old grandson and his marshmellow gun. You can't leave kids alone for two minutes.

My wife said she wants the full grills cut down so the big horn is showing. Sounds like a neat look. What do you guys think about a 3/4 grill?

These have not been polished yet. I need to let them cure for a few weeks before I do that.

JoshK · « **Reply #19 on:** 29 Nov 2009, 12:51 am »

Superb! They look amazing. I do like the 3/4 grill idea. You can always make a seperate grill of the horns if later desire, so they can be independently chosen to be used or removed.

BTW, I read somewhere that you can fix a dented dust cap with scotch tape. Take a piece and roll it onto itself like you are going to hang a poster and put your finger inside. Then touch the dented dust cap and pull it out. Well, lousy explanation, but you get the point.