My First DIY Speakers: Dayton RS 3-way towers

[lionsnob]

Hello!

I’ve been lingering here for a few weeks and would like to embark on building my own speakers. I’d like to build these first:

Speakers

I see the cutout detail here:

Cutout

I have a few questions before I start building the enclosures. Sorry if these have been asked/answered before, I did try to search the boards for answers and these are the questions I have left.

1) I’ve seen people using MDF and some use birch plywood. I like the look of the birch plywood better, but looks aren’t as important to me as sound. Any advantage acoustically to using birch plywood vs. MDF?

2) In the cutout, it asks for 1” thick (1/2 and 1/2). Does that mean two 1/2 inch boards stacked?

3) When I assemble the enclosures, do I use glue to keep them together? If so, what glue? (<- This question seems really stupid to me, but I couldn't find the answer )

Thanks!
Steve

[cjd]

You can get 1" MDF

I used birch ply, so I had to stack and glue two 1/2" sheets.

If you don't have the facilities to properly clamp full sheets, you'll have to do it after they're cut. Because you need that glue joint to be GOOD. Plain yellow wood glue (titebond 1) is great.

Also, PLEASE note the DADO comment. If you do not dado (table saw or router! I think I'd go the router method in the future) these cut sheets are not accurate.

Ply vs MDF is a little gain, little loss, in both directions. Neither is particularly inferior, and a combination of both may get you the best all around results. If you're going to leave them unfinished I would go with birch ply personally (oh, I did! hey. ) Really, with the bracing scheme in these I think there's not much one way or another to worry about.

This is a somewhat complex first project. Take your time, make sure you COMPLETELY understand everything before you get going. And if you're even slightly unsure, just ask.

C

[lionsnob]

Wow! Thanks for the tips. I know it's complex but I'll have some help and I'll take it one step at a time. Thanks for the quick response!

I think I'll go with the MDF (seems easier since it comes in 1" thickness) and use the wood router for the dado.

I'm buying the wood this weekend and will cut it during the week. I'll certainly post if I have any questions.

Thanks again cjd.

You can get 1" MDF

I used birch ply, so I had to stack and glue two 1/2" sheets.

If you don't have the facilities to properly clamp full sheets, you'll have to do it after they're cut. Because you need that glue joint to be GOOD. Plain yellow wood glue (titebond 1) is great.

Also, PLEASE note the DADO comment. If you do not dado (table saw or router! I think I'd go the router method in the future) these cut sheets are not accurate.

Ply vs MDF is a little gain, little loss, in both directions. Neither is particularly inferior, and a combination of both may get you the best all around results. If you're going to leave them unfinished I would go with birch ply personally (oh, I did! hey. ) Really, with the bracing scheme in these I think there's not much one way or another to worry about.

This is a somewhat complex first project. Take your time, make sure you COMPLETELY understand everything before you get going. And if you're even slightly unsure, just ask.

C

[Mazeroth]

Be extremely careful when cutting MDF! Make sure you have a very good respirator as you don't want to be inhaling MDF dust, and wear proper eye protection. Also, it's quite heavy so if you can have the place that you buy it from cut it into a more managable size that will save your back.

[lionsnob]

Hmmm...

Can't seem to find any 1" thick MDF around here (metro Detroit), tried Lowe's and Home Depot. The lumber yard is closed today but I'll try them tomorrow. Do I have to go to a specialized store to get it?

Thanks!

[Brian Bunge]

Yeah, you won't find it at HD or Lowe's. There was a supplier in Atlanta that I ordered from all the time. They are the ones I got the MDF from for my big towers. But haven't tried to find anyone down in my area yet. There's always the possibility of laminating 1/2" MDF together as well. I used 3 layers of 1/2" for a 1 1/2" baffle and back on my center channel.

[engr_dave]

There must be places to get 1" MDF in metro Detroit. Try looking up "hardwoods" in the yellow pages or google. Often lumber stores that carry hardwoods also have a variety of specialty veneer plywoods, veneered MDF core, and raw MDF. There are at least three places I know of in Tucson to get 1" MDF... and it's half the size of Detroit! Also, Home Depot may be able to special order it for you.

[dCraig]

Yeah, you won't find it at HD or Lowe's. There was a supplier in Atlanta that I ordered from all the time. They are the ones I got the MDF from for my big towers. But haven't tried to find anyone down in my area yet. There's always the possibility of laminating 1/2" MDF together as well. I used 3 layers of 1/2" for a 1 1/2" baffle and back on my center channel.

Brian. Who is your supplier in Atlanta? I still seem to have trouble locating it here. I went to Atlanta Wood Products, but no luck on 1" stuff..

[Brian Bunge]

The name of the company was Meyer Laminates. They delivered for free to my business that was all the way out I-20 East near Madison. I'm not sure if they sell to individuals or not. I never went to their location. You could give them a call and find out though. If you do call, make sure you ask for A grade and not shop grade MDF.

You can reach them at 404-699-3900.

[lionsnob]

Thanks Brian!

I actually found a local lumberyard that ordered some for me. I can finally start working on it this weekend! I'm pumped

[ch83575]

Lionsnob, where did you find it?
I am in Ann Arbor and I havent had much luck finding anything out here like that, and I would be interested in who you used. The other thing I am always looking for is hardwood veneered ply other than oak or birtch (cherry or walnut perhapse), but nobody around here seems to deal with sheet-goods to the public (there is a specialty plywood place in A2, but they only deal in quantity)

Thanks
-Chad

[Martyn]

Bear in mind that the quality and density of MDF varies widely. You'll probably do better at a specialised hardwood supplier than at HD.

[lionsnob]

Chad-

I'm over in Canton and there's a place called Man's Lumber on Michigan Ave. between Beck and Canton Center. They ordered the 1" for me and it came in about three days later. I believe they had the 3/4" in stock.

Lionsnob, where did you find it?
I am in Ann Arbor and I havent had much luck finding anything out here like that, and I would be interested in who you used. The other thing I am always looking for is hardwood veneered ply other than oak or birtch (cherry or walnut perhapse), but nobody around here seems to deal with sheet-goods to the public (there is a specialty plywood place in A2, but they only deal in quantity)

Thanks
-Chad