Jensen 1071 Build

[JonMarsh]

+2 for MLCS
Jon: have you considered doing that line array as Open Baffle, similar to young John's project?

Pretty much decided THESE will be the mid woofers, and it will be a corner system, monopole line array.





Very smooth SPL response, and very low distortion.





My apologies for the minor thread-jack!

[JonMarsh]

I don't know why, but it seems to happen to everyone, me included, that space for the crossover is the last thing that gets attention and planning... which can really bite you in the butt later on!

[sdl2112]

Looking good :T Plenty of room for the x-over I see...mine is going to be a little tight.

[Steve Manning]

For Jon ..... "fiddly bits"

As Jon would call it, lots and lots of "fiddly bits". Between the baffles and the crossover compartment, 62 - 8/32" brass inserts ......







Checking the fit ... for a change I got the inserts where they were supposed to be. Now I have to order some black screws from McMaster-Carr to blend in with the drivers.

[Steve Manning]

Working on the crossover compartment

Framing the crossover compartment with baltic birch plywood ..... I figured I would have less of an issue with splitting once I screwed in threaded inserts.





You can also see the crossover board that will hold the parts and the holes for feeding wiring in and out of the compartment .....

[Steve Manning]

Serious progress continues! Got a notion when you'll be putting them together with drivers, or is the allocation of spare time too iffy this time of year?

Unfortunately the second of the two. I was out of town this past weekend for family commitments, though I did visit a killer lumber yard up in Pennsylvania and picked up some nice bubinga that I will be using to trim out the bottom of the cabinets. I have the better part of two weeks off work over xmas but I will be out north of Seattle for half of that visiting my family and the remainder in Maryland with my wife's family. Spending time with family is of course the important thing, but it's still going to kill me knowing I could be working on the project especially that things are starting to get some what close.

[JonMarsh]

Serious progress continues! Got a notion when you'll be putting them together with drivers, or is the allocation of spare time too iffy this time of year?

[Steve Manning]

Another big mess

Another one of the big honking MLCS bits ......



This time put a bevel on the back side of the mid and bass holes ....







And then the sawdust clean up ... again.

[Steve Manning]

Those baffles are looking very nice Steve :T

Thanks Scott ...Can't wait to get them glued in place, but I'm making sure I get all the internal work done first so I don't arrive at another duh moment and discover there in the way.

[Steve Manning]

+2 for MLCS I've bought all my bits from them for several years. Plus, I've got a few of these Merle clamps that I've used on many cabinet glue-ups:
http://www.mlcswoodworking.com/shops...rle_clamp.html I've got a 1 1/4" roundover, but have yet to need such a large radius edge treatement.
Steve, I built my router table cabinet with a door to the router compartment that seals, and a 3" vac hose outlet on the back of that compartment - works great, along with a small hose outlet on my fence. With your skills, you could easily build and attach a door to your cab and add a hose outlet.
Jon: have you considered doing that line array as Open Baffle, similar to young John's project?

Hank, Modifying the router table cabinet dust collection is now on the to-do list, along with a cyclone pre-stage for my dust collector that's been on the list. I have one of these http://www.rockler.com/product.cfm?page=11312 that I am thinking about attaching to the back of the cabinet with some quick disconnect clamps and then put in a tee with a smaller hose to the fence like your suggesting. What ever I do it has to go on and off quickey so I can change bits out easily.

[JonMarsh]

+2 for MLCS I've bought all my bits from them for several years. Plus, I've got a few of these Merle clamps that I've used on many cabinet glue-ups:
http://www.mlcswoodworking.com/shops...rle_clamp.html I've got a 1 1/4" roundover, but have yet to need such a large radius edge treatement.
Steve, I built my router table cabinet with a door to the router compartment that seals, and a 3" vac hose outlet on the back of that compartment - works great, along with a small hose outlet on my fence. With your skills, you could easily build and attach a door to your cab and add a hose outlet.
Jon: have you considered doing that line array as Open Baffle, similar to young John's project?

That concept originated back in 2003 or so, and I actually had a bunch of MCM 6-1/2" carbon fiber mid woofers, which mostly measure sort of decent, but had an impedance bobble in a the midrange that upon investigation turned up to be a cone resonance.

Sure, dipole is possible, but opens up more worms and questions- like how dipole do you want it to be? where will one tolerate flare as you fall out of dipole operation going up in frequency?

since John IS doing this, takes the pressure off of me... :W

Not sure what midwoofer I'd use if I was to try this... would have to be something pretty clean, but just up to 1 kHz or so (600Hz crossover). But Geez, can you imagine what a half dozen Illuminators per side would cost!!??!? :E

ON the other hand, a built in, in the corners of my GF's family room would be interesting for HT... No BSC, position the height for seating to standing listening position... RS180's? NatalieP style crossover? Hmmmm... :yesnod:

[sdl2112]

After getting the baffles glued up, I put an 1 1/4" round over on the edges ..... talk about making a major mess of the garage !!!

Those baffles are looking very nice Steve :T

[Hank]

+2 for MLCS I've bought all my bits from them for several years. Plus, I've got a few of these Merle clamps that I've used on many cabinet glue-ups:
http://www.mlcswoodworking.com/shops...rle_clamp.html I've got a 1 1/4" roundover, but have yet to need such a large radius edge treatement.
Steve, I built my router table cabinet with a door to the router compartment that seals, and a 3" vac hose outlet on the back of that compartment - works great, along with a small hose outlet on my fence. With your skills, you could easily build and attach a door to your cab and add a hose outlet.
Jon: have you considered doing that line array as Open Baffle, similar to young John's project?

[Steve Manning]

MLCS is great, aren't they? I've got some of their big honkers, too, though the project idea I bought those for has been languishing a long time (line array's).


And unbelievably, I even found a pic (though not on my current Mac).



The woofer only assembly is:



Well, I'm already running out of places to put stuff like this... so... umm, ermm, well, never say never...

:rofl:

Yep, I love MLCS, I'm awaiting a few more bits to be delivered from them as we speak. Their prices are very reasonable and with their Katana line you have the option of buying a higher quality bit if you know your going to be using it a lot. I think what I like the most is the free shipping, buy one bit or ten, it's the same price ..... free.

Like the line array concept by the way. :T

[Steve Manning]

Hmm, I was thinking double that. Not bad at all. How many passes did you take to get to the final pass?

I think I ended up doing about 4 or 5 passes. If I had a larger router I might have been able to do fewer but the slower approach seemed to pay off pretty well since the round overs turned out pretty smooth, and the router is still happy.

[JonMarsh]

Actually not too bad, $39 at http://www.mlcswoodworking.com/shops...ound_over.html they have pretty good prices and free shipping on everything.

MLCS is great, aren't they? I've got some of their big honkers, too, though the project idea I bought those for has been languishing a long time (line array's).


And unbelievably, I even found a pic (though not on my current Mac).



The woofer only assembly is:



Well, I'm already running out of places to put stuff like this... so... umm, ermm, well, never say never...

:rofl:

[oneplustwo]

Hmm, I was thinking double that. Not bad at all. How many passes did you take to get to the final pass?

[Steve Manning]

That's a ridiculously large round over bit! Probably worth more than my entire router setup!

Actually not too bad, $39 at http://www.mlcswoodworking.com/shops...ound_over.html they have pretty good prices and free shipping on everything.

[oneplustwo]

That's a ridiculously large round over bit! Probably worth more than my entire router setup!

[Steve Manning]

Making a big mess ......

After getting the baffles glued up, I put an 1 1/4" round over on the edges ..... talk about making a major mess of the garage !!!







Even though I used the dust collector I apparently need to make some modifications to my dust collection setup on the router table!

[Steve Manning]

Very nice work, Steve. I'm liking that heavy duty workbench! Did you build it?

Thanks Hank. Yes I did build the workbench, other than time, it cost me less than a third to do it myself rather than buy one. It's a big jump up from saw horses and plywood to build things on. A 4" thick top with 5" square legs tend to stay where you put it, which is handy when trying to put things together.

Steve

[Hank]

Very nice work, Steve. I'm liking that heavy duty workbench! Did you build it?

[Steve Manning]

Circles and more circles...

Continued with baffle work, had to get a larger Jasper jig for the woofer cutouts ....





Checking the fit of the drivers .....



All of the layers done ....

[Steve Manning]

What you probably could have done was to use the same-shaped piece for the other side underneath the piece you wanted to round over, do that piece, then flip in over and round over the edge of the other piece. I've done exactly this before.
Paul

Good idea Paul, I'll keep it in mind for the next time that I'm sure to to the same thing.

[Paul K.]

What you probably could have done was to use the same-shaped piece for the other side underneath the piece you wanted to round over, do that piece, then flip in over and round over the edge of the other piece. I've done exactly this before.
Paul

[JonMarsh]

That is a familiar sort of feeling- "Duh!" moments! Innovation is the key to recovery, and you've got yours well under control! :W

[Steve Manning]

A duh moment

Went to put a 1/2" round over on a 1/2" thick board and come to the realization that there is no where for the guide bearing to sit on !! Had to make a template the same shape as side cladding to get around that.







Quick look on the cabinet to see how it looks ...

[diamondjoequimb]

Impressive cabinet construction!

[Steve Manning]

I'll be using rattle can spray paint...I have my fingers crossed. I've done a lot of research for surface preparation. It would be interesting to hear what technique your guy uses.

Your build is looking good :T

I think he uses a compressor and spray gun, typical stuff for painting a car I guess. We have to get together and go over logistics and pick colors before we get started.

I have an Earlex sprayer that I have used to paint a tv stand that turned out pretty well, but I want to get the best finish I can and figured I'd use someone that does this at a more professional level then what I could do.

[sdl2112]

Hey Scott ..... I'm going to be painting these, actually I'm having them painted by a guy I work with that does car restoration. Then a little bubinga trim around the bottom of the cabinet, something like the pictures I posted at the beginning of the thread.

Steve

I'll be using rattle can spray paint...I have my fingers crossed. I've done a lot of research for surface preparation. It would be interesting to hear what technique your guy uses.

Your build is looking good :T

[Steve Manning]

Trimming baffles

After trimming baffle to length ....





After flush trimming the baffle. Found that the attached vacuum hose did very little to catch the mdf dust since the bit extended so much lower than the bottom of the router. Had to open both garage doors and turn the leaf blower loose to clean up the mess ....

[Steve Manning]

Starting the baffles

Getting things setup for the baffles to go in place....







Not as beefy as one of Jon's baffles but at 2" thick they still add some appreciable weight to the cabinets .......

[Steve Manning]

Nice Steve, how do you plan on finishing them...paint, veneer...?

Hey Scott ..... I'm going to be painting these, actually I'm having them painted by a guy I work with that does car restoration. Then a little bubinga trim around the bottom of the cabinet, something like the pictures I posted at the beginning of the thread.

Steve

[sdl2112]

Nice Steve, how do you plan on finishing them...paint, veneer...?

[Steve Manning]

Side Cladding

While trimming boards to size early in the project I end up with a thin piece of baltic birch plywood that came in handy for laying out the curve for side cladding pieces ......





I ended up with a pretty good curve to follow on the band saw ....



Temporarily attached one of the sides to get a feel of how it would look ....

[Steve Manning]

After getting the second side on I was not satisfied with how the back sounded during a knuckle test, even with the carpet tiles added. The bracing worked very well on the sides but was not doing as good a job on the back. So I decided to add an additional layer of 1/2" mdf to the back area. This seemed to balance things out well, even though these things are starting to get a bit heavy!







One cabinet with and without the extra layer.

[Steve Manning]

Gluing on the final side .....



Trying out the new sanding block for a little clean up .....

[Steve Manning]

Make sure to use some 2"+ rigid fiberglass or Bonded Logic inside the cabs behind the mid and woofer. Looking excellent so far. Thanks for all the build porn!

Greg

Thanks Greg. I was thinking about using some extra wool stuffing from Madisound that I have for the mid. cabinet and picking up a 5 lb bag of Acousta-Stuf from Parts Express for the bass cabinet.

Steve

[gbegland]

Make sure to use some 2"+ rigid fiberglass or Bonded Logic inside the cabs behind the mid and woofer. Looking excellent so far. Thanks for all the build porn!

Greg

[Steve Manning]

Great job with the carpet tile... :T What did you use for the adhesive?

Thanks ...... I used Loctite Pro Line Premium Construction Adhesive and threw some staples in to hold things in place will that set up. Seems to be holding pretty well so far.

[sdl2112]

Great job with the carpet tile... :T What did you use for the adhesive?

[Steve Manning]

Cabinet Dampening

Troels design called for using bitumen and felt on the cabinet walls for dampening. After discovering that the type of felt he uses is tough to find in the US, and not wanting to deal with the smell of the bitumen, I decided to give an idea of Tony Gee's over at Humble Homemade Hifi a try .... carpet tile.









It took a while to get everything cut and glued into place but it has made a big difference with the knuckle test on the walls.

[Steve Manning]

Pics

Checking out port tube fit .......



Cabinet starts getting some glue .......

[Steve Manning]

Steve, thanks for the inspiration...I started my build thread

On my way over to look .......

[sdl2112]

Cool Scott, I'm looking forward to your thread.

Steve, thanks for the inspiration...I started my build thread