DIY causes sunburns! The SunTwos

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  • Patrick Sun
    Super Senior Member
    • Aug 2000
    • 1380

    DIY causes sunburns! The SunTwos

    6/17/01

    Obviously, I'm not as burned out on DIY as I thought I was, though I was sunburnt from doing some routing on the front baffle (Photos 5-8) outside on Sunday. Here's an update of the start of my next project, conventional 2-way speakers to be used as rear speakers, which I've dubbed: The SunTwos. I've tried to minimize the number of photos since most of the construction process has been covered on my SunOnes webpage.

    Photo 1 : Here's the cut up MDF, plywood, and bracing. I also had the front baffle rounded over with a 3/4" roundover bit.

    Photo 1 : I mark a border around the 1/4" thick plywood layer, which I will glue to the backside of the front baffle. This is to give the T-nuts (for the drivers) something to sink their teeth into when I pound them into the plywood later. Here is a shot of the glue that I applied to the backside.

    Photo 1 : Got clamps? Just applying some clamping pressure to the plywood being glued to the backside of the front panel.

    Photo 1 : Here I spend some time marking front baffles for the driver holes, and the flushmouting perimeter. Fred tried to give me the "paws-up"sign (I'm sure that's what he's thinking). I re-use the same driver placement as I did with the SunOnes. The tweeter center is located 3" of the top, and 3/4" off the center line. The midwoofer center is located 9.5" from the top, and 1/2" off the center line. The front baffle is 10" wide and 17" tall.

    Photo 1 : Based on lessons learned on my previous attempts at flushmounting drivers, I decided to be a little smarter with the flush mounting of the drivers. So here you not only see the front baffles with the tweeter holes cut out, but you see a test piece I used to vertify the flushmount diameter, and the tweeter hole diameter. And somehow I still made one of the 2 flushmount diameters too wide - will need to slap some woof filler or caulk in the gap. Doh!

    Photo 1 : Since the midwoofers have that funky truncated edges to them, I carefully route in the straight edges for them on the baffles. My router has a straight edge side to its base, so I just used a scrap MDF clamped on top of the baffle to give me a "fence" to guide the straight edge routing.

    Photo 1 : Here's a shot of the router doing its thing. Currently it's doing the flushmounting of the midwoofer hole. That's my trusty Sears Router Guide that I use as a circle jig.

    Photo 1 : After about 3.5 hours under a tree, but still managed to get my arms and feet burnt, I finish the driver hole routing. Here's a shot of the drivers in the holes on one baffle, and a non-occupied baffle. I wish I were faster getting these holes routed, but I tended to over-check the routing measurements so I don't have to re-do the baffles. I'm sure some people can do this in 1/3 of the time I took.

    That's it for now. Here's the list of stuff to be done next:

    1. Pop in the driver screw holes, and install the t-nuts.
    2. Route in a big circle for the MDF brace that will separate the tweeter from the midwoofer (as in the SunOnes)
    3. Glue/clamp together the sides of the boxes.
    4. Glue the front baffles to the box sides.
    5. Install the bracing.
    6. Install the rear panel (dual-input terminal cup and port), countersink the screw hole for the wood screws.
    7. Create the crossover panel
    8. Screw in the drivers and connect them to the crossover, and then to the terminal cup's dual input.
    8. Test and listen.




    PatCave; HT Pix;Gear;DIY Projects;DVDs; LDs
    PatCave; HT Pix;Gear;DIY Projects;DVDs; LDs
  • Lex
    Moderator Emeritus
    • Apr 2001
    • 27461

    #2
    What? You mean you cut the number of photos down to 2500? lol JK. Good work Patrick. Perhaps the next ones can be the Sun Burnt Ones.

    Lex
    Doug
    "I'm out there Jerry, and I'm loving every minute of it!" - Kramer

    Comment

    • Patrick Sun
      Super Senior Member
      • Aug 2000
      • 1380

      #3
      Actually, I've been giving this a lot of thought, and I think I should call these speakers:

      The Sun Burnt Buns.




      PatCave; HT Pix;Gear;DIY Projects;DVDs; LDs
      PatCave; HT Pix;Gear;DIY Projects;DVDs; LDs

      Comment

      • Andrew Pratt
        Moderator Emeritus
        • Aug 2000
        • 16507

        #4
        pat usually I love to see your photos' but if you post pics of your sun burnt buns I might have to delete that post for pornographic content LOL




        Comment

        • Patrick Sun
          Super Senior Member
          • Aug 2000
          • 1380

          #5
          Oh you don't have to worry. I'm afraid that "moon" would cause the tide to rise and flood California!




          PatCave; HT Pix;Gear;DIY Projects;DVDs; LDs
          PatCave; HT Pix;Gear;DIY Projects;DVDs; LDs

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          • Patrick Sun
            Super Senior Member
            • Aug 2000
            • 1380

            #6
            Okay, folks, I finally got off my lazy butt, and finished up the SunTwo's this weekend. I'll be putting together a construction webpage soon. Don't expect it to be super-detailed, as I tried to streamline the number of photos (but still could only edit the photo count down to around 70 photos).

            Preliminary listening sessions with the new boys: a little hot on the tweeter end, but I don't see a problem taming the tweeter output by 1-2dBs. There is no midrange glare to speak of, which means the midrange's XO is doing its job commendably. I'll be doing some measurements later in the week, time permitting. Otherwise, they sound pretty good, and will sound better once I get the tweeter level to match the midrange (and still keep some bit of baffle step compensation intact).

            Here's a couple of shot of the new babies:




            PatCave; HT Pix;Gear;DIY Projects;DVDs; LDs
            PatCave; HT Pix;Gear;DIY Projects;DVDs; LDs

            Comment

            • James W. Johnson
              Member
              • Jun 2001
              • 68

              #7
              Nice job Patrick. Are you going to keep them that low to the ground?
              pics

              Comment

              • Patrick Sun
                Super Senior Member
                • Aug 2000
                • 1380

                #8
                No, I just use the short speaker stands for photo-taking. They'll sit on 29" tall stool for the interim unless I make some matching speakers stands for them.

                Here's the Construction Webpage for the SunTwos.




                PatCave; HT Pix;Gear;DIY Projects;DVDs; LDs
                PatCave; HT Pix;Gear;DIY Projects;DVDs; LDs

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                • Patrick Sun
                  Super Senior Member
                  • Aug 2000
                  • 1380

                  #9
                  After much tweaking, I have gotten rid of most of the peakiness around 5KHz, this graph shows the most current XO's response.

                  I listened for about an hour with this latest XO change last night, and it's definitely a step in the right direction. I will evaluate it some more this weekend.




                  PatCave; HT Pix;Gear;DIY Projects;DVDs; LDs
                  PatCave; HT Pix;Gear;DIY Projects;DVDs; LDs

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                  • Patrick Sun
                    Super Senior Member
                    • Aug 2000
                    • 1380

                    #10
                    Okay, hopefully this will be my final XO tweak. Here's the ResGraph version of the current XO's frequency response .

                    This required just playing around with the L-pad resistors to get what I thought sounded "as right" as possible for the combination of drivers and the enclosure design.

                    Anyhow, the tweeter sounds more balanced w/r/t the midwoofer output, and the rising tweeter output I used to have is but a distant memory.




                    PatCave; HT Pix;Gear;DIY Projects;DVDs; LDs
                    PatCave; HT Pix;Gear;DIY Projects;DVDs; LDs

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