After reading a lot on various forums, and thinking and talking a lot about it, I decided to kick off a new design, new and different for me in many ways. I'm sure I'll learn a lot from it.
Firstly, it's a 4-way. I've never done a 4-way design before. And since it'll be a passive crossover, it's going to make me stretch whatever little I know about crossover design and speaker measurements.
Secondly, it'll be lower order crossovers. I'm currently toying with the idea of 2nd order slopes. I may even try 1st order on some of the crossover points. 4-way design means three crossover points, so I have a lot of points to pick and choose from.
Thirdly, as a consequence of the shallow slopes, I'm choosing drivers by the smoothness of their SPL curves above all else. This means that I'm ignoring distortion behaviour and all other attributes of the drivers.
Fourthly, this will be the first time I'll experiment with stepped baffles. Let's see what the combination of multiple-way, shallow slopes and stepped baffles gives me.
Fifth, I am thinking of some weird enclosure experiments for the midrange drivers -- I'll make their chambers neither sealed nor open at the back. I'm thinking of trying wide-diameter PVC tubes on the rear wall of their chambers, like ducted ports, except that they'll be fairly tightly filled with Polyfill type fibre to absorb the back wave. The aim is to neither reflect the rear wave, nor allow it to emerge at the rear -- just absorb it. Will it work? Who the hell knows? But it'll be great if it does work.
The trigger for a lot of this was from the writings of Troels Gravesen. Many others have written about the benefits of multi-way designs -- many designers seem to consider a 3-way as the minimum for decent performance. I've done a 3-way, though active, with the Darbari, so I decided I'll push a bit further this time, hence 4-way. And I'm intrigued by Troels Gravesen's comments about physical time alignment -- he seems to be doing this for pretty much all his designs.
Since I am very unsure of my own capabilities to design such a beast, I decided to keep costs low, therefore chose inexpensive drivers. After searching through Madisound, Parts Express and other sites, I decided to go with inexpensive options closer to home -- I picked SB Acoustics from DIYAudioParts for 3 out of the 4 drivers.
The main aim for driver selection was "well behaved" drivers -- drivers whose SPL curves are so benign that I can afford to let them play with wide overlap from one another without struggling to cut out cone-breakup resonances or other unevennesses. Therefore, paper or poly cone drivers seem to be the only viable drivers.
When building a 4-way design, the natural driver sizes seem to fall into the following structure:
It's really hard to find midrange or midbass units which can take shallow slopes at their upper end (i.e. their low-pass filters) and still sound decent. Most hard cones, which are good at reproducing accuracy and detail, have severe cone break-up at their upper ends, which means their crossover slopes will need to be at least 4th order to let me suppress their break-up regions by at least 50 dB or more. For metal-cone drivers, 70 dB suppression is preferable.
With these criteria, the drivers which fit the bill most easily are the full-range drivers. The better full range drivers have a long, flattish SPL curve which will behave well with shallow slopes because they have no ugly SPL peaks even 3 octaves beyond their upper crossover point. I found the following drivers pretty suitable:
Keeping in mind the costs and ease of procurement, I chose
The crossover points will be
I have no idea how it'll turn out. Watch this space, wish me luck, and come over to my place in New Bombay for a listen when it's all done.
Firstly, it's a 4-way. I've never done a 4-way design before. And since it'll be a passive crossover, it's going to make me stretch whatever little I know about crossover design and speaker measurements.
Secondly, it'll be lower order crossovers. I'm currently toying with the idea of 2nd order slopes. I may even try 1st order on some of the crossover points. 4-way design means three crossover points, so I have a lot of points to pick and choose from.
Thirdly, as a consequence of the shallow slopes, I'm choosing drivers by the smoothness of their SPL curves above all else. This means that I'm ignoring distortion behaviour and all other attributes of the drivers.
Fourthly, this will be the first time I'll experiment with stepped baffles. Let's see what the combination of multiple-way, shallow slopes and stepped baffles gives me.
Fifth, I am thinking of some weird enclosure experiments for the midrange drivers -- I'll make their chambers neither sealed nor open at the back. I'm thinking of trying wide-diameter PVC tubes on the rear wall of their chambers, like ducted ports, except that they'll be fairly tightly filled with Polyfill type fibre to absorb the back wave. The aim is to neither reflect the rear wave, nor allow it to emerge at the rear -- just absorb it. Will it work? Who the hell knows? But it'll be great if it does work.
The trigger for a lot of this was from the writings of Troels Gravesen. Many others have written about the benefits of multi-way designs -- many designers seem to consider a 3-way as the minimum for decent performance. I've done a 3-way, though active, with the Darbari, so I decided I'll push a bit further this time, hence 4-way. And I'm intrigued by Troels Gravesen's comments about physical time alignment -- he seems to be doing this for pretty much all his designs.
Since I am very unsure of my own capabilities to design such a beast, I decided to keep costs low, therefore chose inexpensive drivers. After searching through Madisound, Parts Express and other sites, I decided to go with inexpensive options closer to home -- I picked SB Acoustics from DIYAudioParts for 3 out of the 4 drivers.
The main aim for driver selection was "well behaved" drivers -- drivers whose SPL curves are so benign that I can afford to let them play with wide overlap from one another without struggling to cut out cone-breakup resonances or other unevennesses. Therefore, paper or poly cone drivers seem to be the only viable drivers.
When building a 4-way design, the natural driver sizes seem to fall into the following structure:
- a dome tweeter: one inch or smaller, since I can afford to cross over to it even as high as 3KHz
- a 4" or 5" upper mid
- an 8" lower mid
- a 12" or 15" woofer for the bottom 3 octaves or so
It's really hard to find midrange or midbass units which can take shallow slopes at their upper end (i.e. their low-pass filters) and still sound decent. Most hard cones, which are good at reproducing accuracy and detail, have severe cone break-up at their upper ends, which means their crossover slopes will need to be at least 4th order to let me suppress their break-up regions by at least 50 dB or more. For metal-cone drivers, 70 dB suppression is preferable.
With these criteria, the drivers which fit the bill most easily are the full-range drivers. The better full range drivers have a long, flattish SPL curve which will behave well with shallow slopes because they have no ugly SPL peaks even 3 octaves beyond their upper crossover point. I found the following drivers pretty suitable:
- https://www.madisoundspeakerstore.c.../markaudio-alpair-7p-paper-cone-4-full-range/ -- 4" Mark Audio driver, $79, for upper mid
- https://www.parts-express.com/dayton-audio-rs100p-8-4-reference-paper-midwoofer-8-ohm--295-359 -- 4" wide-range driver, $33, for upper mid
- https://www.madisoundspeakerstore.c...e-ca15rly-h1216-5.5-coated-paper-cone-woofer/ -- 5.5" woofer, $86, for upper mid
- https://www.parts-express.com/dayton-audio-dsa115-8-4-designer-series-aluminum-cone-woofer--295-524 -- 4" metal cone, $20, cone breakup a border-line case, may be tolerable with a 12 dB slope, for upper mid
- https://www.madisoundspeakerstore.com/approx-8-woofers/scanspeak-classic-p21wo20-8-woofer-poly-cone/ -- 8" poly cone, $85, for lower mid
- https://www.madisoundspeakerstore.c...markaudio-alpair-12p-8-paper-cone-full-range/ -- 8", $157, for lower mid
- https://www.madisoundspeakerstore.com/approx-10-woofers/seas-prestige-a26re4-h1411-10-paper-cone/ -- 10", $156, 10" driver with exceptionally smooth SPL roll-off, for lower mid
- https://www.parts-express.com/dayton-audio-dsa215-8-8-designer-series-aluminum-cone-woofer--295-530 -- 8" metal cone, $50, borderline case of cone breakup depending on the upper crossover point, for lower-mid duty
- the various Fostex full range drivers and other brands
Keeping in mind the costs and ease of procurement, I chose
- https://www.diyaudioparts.com/SB-Ac...ve-Soft-Fabric-Dome-Tweeter--5-ohm_p_592.html
- https://www.diyaudioparts.com/SB-Acoustics-SB13PFCR25-08-5-Paper-cone-Woofer--8-ohms_p_958.html
- https://www.diyaudioparts.com/SB-Acoustics-SB20PFC30-8-8-Paper-Cone-Woofer-8-ohms_p_629.html
The crossover points will be
- between 150-300Hz for woofer to lower mid
- between 300-700 for lower mid to upper mid
- between 2.5KHz and 3.5KHz for upper mid to tweeter
I have no idea how it'll turn out. Watch this space, wish me luck, and come over to my place in New Bombay for a listen when it's all done.

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