3 Way Speakers with Separate Enclosures for Bass & Mids

[sadik]

Its been a quite long time since I last shared my Projects on our Forum. So now i am up with something Big. I can say it will be a monster.

I am up with a new project a 3 way tower with Three Individual enclosures stacked one above another. Interlocking is provided so the enclosures wont slip off & Isolation is provided for interlock joint to absorb the vibrations and prevent any kind of rattling noise, Image of same will be shared later once i have them in my hand.

So moving ahead, The Bottom Enclosure will be Bass, Middle will be for Mids & Highs & again top will be for Bass. Like the below image for better understanding. Total Height will be more than 7ft.

I don't wanna disclose much about the drivers so i will not mention any details about it except for their sizes. The Bass driver will be 15 Inch, Mids will be 10 Inch & Highs will be Ribbon Horn

I have chosed HDF as the construction material having thickness 25mm, The Finish enclosure will be veneered. I have chosen a off white shade veneer and decided later to stain it with our choice of shade. The Veneer is glued to HDF before cutting. It was glued & then pressed on a 100 TON hydraulic press and left overnight for the glue to dry. Its like 10 trucks stacked one above the other on the glued sheet.

Below are photos of Cutting on CNC router

The 45 Deg cut on the edges to match the flow of veins of veneer on all sides will be done with circular saw. This job will require a great precision and will need jig to achieve the accuracy it need. And yes Challenge accepted Because I know i can do it .

I will share the image of Jig soon.

Sadik

 

[MaSh]

Oh goodness that a monster in the making. 7 foot tall with 2 15" bass drivers and a 10" mid, is that for a living room?

Eager to see how it all comes together. All the best.

MaSh

 

[arunkvivek]

Sadik, your work reminds me of Javad Shadzi. Extreme woodworking! 7 feet ? Duh, I am struggling with 34 inches. Hats off!!!

 

[Mano]

Good luck on your new project. Reminds me of the yesteryear Infinitys and JTRs at present but with different sort of driver placement,

 

[Kannan]

That is one mamoth build. I am sure this one is going to be one more eye candy.

 

[sadik]

The Preparations have started.

HDF 25mm + 4mm veneer + Glue, With a total of 29mm Thick. I will have to cut all 4 edges of all panels in 45 Degree to match the Veneer pattern or grains whatever we call it.

So in 45 Deg the total depth of cut was 41mm. The HDF just took away a hell of my saw blade, It was a genuine Makita wood blade which came along with the circular saw. This blade it got burnt see below the black spots.

I had to use the Metal cutting Blade (Generally used to cut Aluminium sections) to cut this HDF. With this blade the cutting was is fine, so this blade is now approved for further use.

Checking the Degree on a Rough panels. One should not blindly trust with the markings which are made on powertools, It took at least 7 to 8 cuts to make the degree precise.

Checking the Matching of Both pieces.

I am not concern about the matching the pattern lines of veneer in the below photo. I am just concerned about how well I am matching the corner. And I am really very much satisfied with the result.

Sadik

 

[mpw]

nice going sadik...

is the cross over already decided / made ?

 

[sadik]

nice going sadik...

is the cross over already decided / made ?

Thank You Bro,

The Crossover is designed, but yet to be made.

Below is the Photo of the cutting blade i am using. This Blase is used to cut aluminum sections.

The marking Jig which i mentioned in my first post.

Below is the video how i am using it. it will save huge amount if my time.

The Demo Wooden panel in Short the Final results. This chamfer will be done to all the six panels of the enclosure. In total there are 6 Enclosures ... so lot of work to do. I will start the actual work from tomorrow.

Sadik

 

[sadik]

Before I post any update on my thread, I don't no why all my previous photos in this thread are missing, I can just see the video which I have shared on the above post. Its not just this thread but in all my earlier threads too many photos are missing. Admins can you clarify whats the matter here.

I am sharing all my photos through google photos. I think if my work is not visible to members then there is no use to share my project. Additionally I would also like to clarify that the photos are visible only for first 2-3 days then they just disappear.

 

[SanjeevM]

Sad.

 

[rikhav]

Sadik Bhai
Why don't you upload images to website server only
I have been doing that and none of the images stop showing
Only thing is you will need to reduce size of the image with any software and then upload

 

[Hiten]

Additionally I would also like to clarify that the photos are visible only for first 2-3 days then they just disappear.

Sadik,
Nice work !
- - -
third party image hosting is dicey affair. They are time bound. Sometimes they remain for few days some time for few months. Probably depends on the account setting of third party image hosting website. All third party image hosters of yesteryears are closed or severely restricted. For example Imageshack and tinypics.
Best will be to host images on hifivision by attaching required resolution images.
Regards.

 

[sadik]

Sadik Bhai
Why don't you upload images to website server only
I have been doing that and none of the images stop showing
Only thing is you will need to reduce size of the image with any software and then upload

I think there is limited web space available for every member to upload image. The images I upload will take all my alloted space, hence I prefer uploading images from google photos.

Sadik,
Nice work !
- - -
third party image hosting is dicey affair. They are time bound. Sometimes they remain for few days some time for few months. Probably depends on the account setting of third party image hosting website. All third party image hosters of yesteryears are closed or severely restricted. For example Imageshack and tinypics.
Best will be to host images on hifivision by attaching required resolution images.
Regards.

I know Imagehack & Tinypics have been cload, but I am using Google Photos, and this service is still running. I cant figure out is something wrong that i have been following while uploading images from google photos.

 

[rikhav]

Okay...
I was not aware about limit for each user .

 

[aeroash]

I think there is limited web space available for every member to upload image. The images I upload will take all my alloted space, hence I prefer uploading images from google photos.



I know Imagehack & Tinypics have been cload, but I am using Google Photos, and this service is still running. I cant figure out is something wrong that i have been following while uploading images from google photos.

Upload images as attachments.

 

[sadik]

Let me try to upload the photos of my updated project.

Removed all the burrs on edges of the internal braces with the help of router. helped saving a lot of time.

I am using round over bit of radius 6 mm


Result


Now moving ahead with the 45 Deg Cutting of each panel on all 4 sides to match the Veneer Pattern on all sides. I had already made one enclosure so whatever the difficulties i faced while making the enclosure i have overcome with the solution for remaining enclosures.

In 1st enclosure i faced the burrs & chipping problem on the edges during cutting. To overcome this issue I have used masking tape on all 4 sides of the cutting plane, it can be seen in below image. Its very time consuming job to apply the masking tape on all panels.




After Cutting


Closeup after removing the masking take. A Burr & Chip free clean cut


Another update is related to my Tool Collection. Got some Clamps. No matter how many clamps you have you will always be running out of them. These are 36inch Heavy duty Irwin Clamps each having force of 272 Kg.



Another update is related to Jasper Jig, One of my friend brought it from US.


Thats the update till today.

Sadik

 

[mpw]

Going good sadik...look forward to see the finished outvome

 

[sadik]

Nice work, I never let my jasper jig nor my Irwin clamps out of my sight!

What is the model no of your Jasper Jig and which router are you using for same (Specify model no of router)

I have total of 28 Irwin clamps
18 Inch Bar clamp (Medium Duty) - 4 Nos
24 Inch Bar Clamps (Medium Duty) - 10 Nos
36 Inch Bar Clamp (Heavy Duty) - 4 Nos
6 Inch Mini Bar Clamp (Light Duty) - 6 Nos.
4 Inch Handy Clamp - 2 Nos
1.5 Inch Handy Clamp - 2 Nos

 

[quad]

wow - drooling!!

 

[rajesh srinivas]

What is the model no of your Jasper Jig and which router are you using for same (Specify model no of router)

I have total of 28 Irwin clamps
18 Inch Bar clamp (Medium Duty) - 4 Nos
24 Inch Bar Clamps (Medium Duty) - 10 Nos
36 Inch Bar Clamp (Heavy Duty) - 4 Nos
6 Inch Mini Bar Clamp (Light Duty) - 6 Nos.
4 Inch Handy Clamp - 2 Nos
1.5 Inch Handy Clamp - 2 Nos

I have done my circle cutting jig DIY,it can do the cut for a radius less then 3in (76mm) as in pics...