Juhi's rounded Bordeaux build

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  • Juhis
    Junior Member
    • Dec 2018
    • 21

    Juhi's rounded Bordeaux build

    My first post and my first speaker build.

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    Some background for this build.
    I'm not an professional in building speakers and calculating crossovers. Since I got some woodworking tools in my garage I started to take bigger challenge to make the best speakers that I can afford and same time show some muscle that I can build something like that.

    After couple of months searching web for complete speaker kits I first found the Finalists. After some issues of getting the needed parts from Europe area my hungry got bigger and I ended up to build Bordeaux's.
    Ordered parts form here and there and also faced some issues to find the tweeter. Anyway I found out that "Arum Cantus AST2560" is same tweeter as "Harwood Acoustics AM 25 AIR Motion Transformer".. Hope this is true since I now got those.. Looks like same anyway.

    Plan is to build these in single cabinet with rounded sides so I need to take some calculations to get the right volume for the cabinets without getting the front baffle sizing modifications. There was 10% rule mentioned in instructions so I ended up making the "Mid/Tweeter" section 10% deeper than original. That way I also got the right volume for bass bin since still kept the tweeter in right height. That 10% deepening should not be an issue Curt said in our mail conversion.

    I got no autocad skills so I draw everything in paper. This took several evenings to get everything in line and eye comforting state.

    For now the project is already ran for three months and I have build thins couple of times during the weeks.
    I will post the pictures here since the things go forward.


    **** Edited ****

    Since there some have been asking for dimensions and drawings for this build I add "base plate" dimensions below.
    Total cabinet size for woofers ended up ~77Liters
    This tells you the cabinet inside dimensions:
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    Total height is 100cm which made it perfect height for tweeter.
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    Last edited by Juhis; 23 November 2020, 03:47 Monday.
  • Juhis
    Junior Member
    • Dec 2018
    • 21

    #2
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    Planning, calculating, drawing.
    I also made the 1:1 drawing of the "base plate" which I used for cutting first piece.

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    First base plate ready for cutting. This were actually not used at all but I used it as a template for cutting the rest.

    Comment

    • Juhis
      Junior Member
      • Dec 2018
      • 21

      #3
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      Ready from raw cutting.

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      Sanding these for equal size. One speaker parts at time.

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      Ready

      Comment

      • Juhis
        Junior Member
        • Dec 2018
        • 21

        #4
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        Cutting the long sides in right angle. Using hand saw and jig to get it straight.

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        Cutting holes for front baffle.
        Self made guide for round shapes

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        Almost ready.. I forgot to take pictures of cutting the tweeter hole.

        Comment

        • Juhis
          Junior Member
          • Dec 2018
          • 21

          #5
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          Giving some Glue for these skeletons. I used polyurethane glue.
          Just remember to sand those MDF's so the glue will attach better.
          I also forgot to do that on some point and it were not an issue..

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          Fitting the pipe and used some screws during the glue dry up. I unscrewed these so no metal parts were left in.

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          I also glued the pipe. This was some semi elastic glue.
          I will check which I used but it were very sticky and after it was dry it was quite hard.. This pipe is not going anywhere.

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          Ready to get some rounded sides!
          At this point I was very nervous how it's going to happen.. No worries it went easy

          Comment

          • ergo
            Senior Member
            • Mar 2005
            • 675

            #6
            Nice project Juhis. I'll wait with interest how you solved the curved sides. That's one type of box I've not tried yet, but there is some urge to try at some point.

            Comment

            • Juhis
              Junior Member
              • Dec 2018
              • 21

              #7
              I made the sides from normal birch plywood. (4mm) 1/8inch thick. I also tried thicker material but it did not curve so easily and I bet it would be much much harder to get curved and glued.
              First I thought that I will laminate four layers but I ended up to stay in three layers since this curved wall seems much harder than flat sides.
              All were glued together with Cascol Polyurethane glue which will slightly puff up to fill possible cambers between the layers.

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              Used three tightening straps to press first layer on body.

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              Another side.

              On second speaker I actually fasten these sides straight to speaker body using short srcews and that method was even easier!
              Just remove those screws after glue has dried and start laminating new layer.
              Time for some warning for using this method: Use quite thin and short screws to avoid MDF to split. It will split very easily!
              No pictures unfortunately of this method unfortunately.

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              Laminating the next layers.
              Plywood comes little bit over the edge to get those layers easily tighten together.
              The lip will be routed away when this process is done.

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              Next layers were joint together using short screws which were left in place over a night.
              Some clamps will work too but I just did not got enough of those.
              This process took some time because I laminated only one layer/side at time.

              Comment

              • Steve Manning
                Moderator
                • Dec 2006
                • 1879

                #8
                Nice idea with the screws ...... To get away from splitting issues I imagine you could also just drill some holes and use some small bolts and nuts instead. Either way, it's looking good.
                Hold on to your butts - It's about to get Musical!



                WEBSITE: http://www.smjaudio.com/

                Comment

                • Juhis
                  Junior Member
                  • Dec 2018
                  • 21

                  #9
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                  Routed the lip away. This process needs steady hands and no rush.

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                  Screwed the front baffle on it's place using the Speaker screw holes.
                  Not glued in place yet since I will try to veneer these separately.
                  Routing the sides in line with sides. Made it around 0,5mm narrower to compensate the veneer thickness.

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                  First panel ready for veneering.
                  I try to veneer the flat area first and after the glue is dried I bend and glue the veneer for sides.
                  No contact glue will be used, just PVA so I need to figure some weight on these and still thinking how I do it for these rounded corners. Maybe some straps or tape. No vacuum available.

                  Comment

                  • Juhis
                    Junior Member
                    • Dec 2018
                    • 21

                    #10
                    Back panel veneered.
                    Open back cut for tweeter.

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                    Comment

                    • TEK
                      Super Senior Member
                      • Oct 2002
                      • 1670

                      #11
                      Looking very nice, and it seems like you are having nice progress.
                      Ate you building one speaker at the time, or both in paralell? If building one at the time, how dar are you planning on taking it before attacking number two?
                      In my build I have always buildt both in paralell, but I see there are differwnt preferences.
                      Guess I’m just afraid that nr. 2 will not be buildt if I do one at the time ;-)
                      -TEK


                      Many of the great achievements of the world were accomplished by tired and discouraged men who kept on working...

                      Comment

                      • Juhis
                        Junior Member
                        • Dec 2018
                        • 21

                        #12
                        Hi TEK,
                        Thanks for nice words :T

                        I'm building both speakers at same time.
                        I'm trying to keep both in same phase so it's easier to keep things same.
                        Because lack of tools I sometimes need to let glue dry over night before I can start the same step with another piece.

                        Yesterday I got crossovers ready. Glued the components on piece of plywood and soldered all together..
                        Not really thought about changing these components ones set in place... lets see if some tuning is needed after all is set. Need to get some measurement tools too!
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                        Another change in plans were making the front baffle corners from real wood not trying to curve the veneer.
                        I made one curved veneered baffle but it did not satisfy my perfectionism. Still looking for right material to fill those corners nicely and also re-veneer the baffle.
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                        Comment

                        • Efalegalo
                          Senior Member
                          • Jan 2007
                          • 139

                          #13
                          Beautiful build!!!

                          Comment

                          • Heli-Tim
                            Senior Member
                            • Nov 2015
                            • 159

                            #14
                            Looking good!

                            Comment

                            • Juhis
                              Junior Member
                              • Dec 2018
                              • 21

                              #15
                              Thanks for cheer up!

                              Some progress has happen again and I glued the front baffle corners.
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                              I also found some wider veneer for my project.
                              This will help me to avoid slots between veneer joints. Since I got none
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                              Soon starts the sanding, staining, Oiling/waxing or varnishing, wiring the speakers and finally some listening.

                              This is getting more and more satisfying while the progress goes forward.

                              Comment

                              • Dave Bullet
                                Senior Member
                                • Jul 2007
                                • 474

                                #16
                                Love it man. These are gong to look fantastic and be acoustically dead.

                                Comment

                                • Juhis
                                  Junior Member
                                  • Dec 2018
                                  • 21

                                  #17
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                                  Veneering the front baffle. Looks quite bad at this point but ended up quite good.
                                  I used the iron to melt the glue in its place quickly. This was quite easy method and beaten the pressing method easily.

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                                  Rough cut holes with sharp knife.

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                                  Sanded with 120grit to 400grit.

                                  Starting the same progress with another box..

                                  Comment

                                  • ergo
                                    Senior Member
                                    • Mar 2005
                                    • 675

                                    #18
                                    Looking very good!
                                    Good that we are starting to see weather around these parts of globe that allows work outside. Even with vacuum and all this sanding is a dusty business.

                                    Comment

                                    • Juhis
                                      Junior Member
                                      • Dec 2018
                                      • 21

                                      #19
                                      Progress
                                      Spread some Light Teak stain on these and for me look is amazing Really pops up the shape of wood!
                                      Next I will add some shine and protect with Danish Oil.

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                                      Comment

                                      • Dave Bullet
                                        Senior Member
                                        • Jul 2007
                                        • 474

                                        #20
                                        Wow - just wow! I'd be mighty proud if I made those!

                                        Comment

                                        • Mikerodrig27
                                          Senior Member
                                          • Feb 2015
                                          • 160

                                          #21
                                          Well those are cool! Great job so far!

                                          Comment

                                          • Juhis
                                            Junior Member
                                            • Dec 2018
                                            • 21

                                            #22
                                            Ready for takeoff!
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                                            Still thinking about building some front shield for extra protection but I just love the look of these as is.

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                                            Back plug not in place on these pics. Just some light stuffing for a start.

                                            Comment

                                            • Juhis
                                              Junior Member
                                              • Dec 2018
                                              • 21

                                              #23
                                              On the listening position.
                                              I know these would like to come even more out from the back wall but this is kind of compromise and first impression is not bad at all!
                                              Open back really gives some stage witch sounds really natural and I cannot hear the sound bounce from the wall.. It just slightly fill the room without ruining the feeling of depth and stereo image. Makes stage wider somehow.

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                                              Some said that there is not much bass but I cant agree. These go were nicely to low40-50 and on my preferences not even need sub. Least for now
                                              My old Infinity Delta 40's were said to be Bass aggressive but the will hit those anytime with linear bass..No highlighting, just accurate, fast and deep. The room and listening position makes a lot on this area.
                                              Mid-range is expectedly superb! I have never heard anything this clear without being too aggressive.
                                              This is the area where the good and bad recordings are separated and it is really nice to get all the details out from records!

                                              Only one slight issue remains with Tweeter and mid crossing point since the tweeter manufacturing changes during the time.
                                              There is slight drop on 2-3kHz and around 5db raise at 4-5kHz which all can be fixed with Crossover tuning. There is own thread for this manner.

                                              After the crossover will get tuned I could post some measurements.
                                              Just need to do more listening since these are not even break in yet!

                                              Last but not least.
                                              Thanks for Jim and Curt for the design!
                                              Last edited by theSven; 10 April 2023, 01:55 Monday. Reason: Update htguide url

                                              Comment

                                              • ergo
                                                Senior Member
                                                • Mar 2005
                                                • 675

                                                #24
                                                Very very nice outcome - congrats! Thank you for recording the build process so well too. I suspect I'll be using some of the 'tricks' for a future project too.

                                                Comment

                                                • Jim Holtz
                                                  Ultra Senior Member
                                                  • Mar 2005
                                                  • 3223

                                                  #25
                                                  Beautiful cabinet work! :T

                                                  I'm very pleased you're enjoying the sound quality. I agree with you on the bass and mids. Curt is working on a temporary solution to the AST2560 issue until a permanent revision can be mad with the new AST2560 design.

                                                  Excellent job and a speaker you can be really proud of!

                                                  Enjoy!

                                                  Jim

                                                  Comment

                                                  • Steve Manning
                                                    Moderator
                                                    • Dec 2006
                                                    • 1879

                                                    #26
                                                    Those turned out very nice. :T
                                                    Hold on to your butts - It's about to get Musical!



                                                    WEBSITE: http://www.smjaudio.com/

                                                    Comment

                                                    • Efalegalo
                                                      Senior Member
                                                      • Jan 2007
                                                      • 139

                                                      #27
                                                      Originally posted by Juhis
                                                      Mid-range is expectedly superb! I have never heard anything this clear without being too aggressive.
                                                      THIS!

                                                      There is really something special about the Accuton. I too was really impressed with the midrange.

                                                      Those cabinets came out beautiful. I envy your woodworking skills.

                                                      In regards to bass, as Curt pointed out in my thread, its very much room dependant. My listening room is basically our family room, which opens up to the rest of the house (e.g., dining area, kitchen, etc.). For me, I needed to increase the tuning a bit to get a slightly more boost in the bottom end.

                                                      Can't wait for you to take measurements. Any chance you can take gated measurements as they are now?

                                                      Comment

                                                      • Juhis
                                                        Junior Member
                                                        • Dec 2018
                                                        • 21

                                                        #28
                                                        Thanks to all of your comments!
                                                        I could not be much more satisfied with the final results.

                                                        Originally posted by Efalegalo
                                                        Can't wait for you to take measurements. Any chance you can take gated measurements as they are now?
                                                        Maybe you can help me out to get measurement correct.
                                                        I posted private message to you.

                                                        Comment

                                                        • TEK
                                                          Super Senior Member
                                                          • Oct 2002
                                                          • 1670

                                                          #29
                                                          Originally posted by Juhis
                                                          Ready for takeoff!
                                                          [ATTACH=CONFIG]29225[/ATTACH]
                                                          Still thinking about building some front shield for extra protection but I just love the look of these as is.

                                                          [ATTACH=CONFIG]29226[/ATTACH]

                                                          [ATTACH=CONFIG]29227[/ATTACH]
                                                          Back plug not in place on these pics. Just some light stuffing for a start.
                                                          Really nice work!
                                                          For me - the feeling of satifaction when walking by, looking at or using something you have buildt yourself and are happy with - that is the main reason for beeing into Do-It-Yourself projects.

                                                          I hope you will enjoy them in many years to come!
                                                          -TEK


                                                          Many of the great achievements of the world were accomplished by tired and discouraged men who kept on working...

                                                          Comment

                                                          • jacket_fan
                                                            Member
                                                            • Oct 2006
                                                            • 83

                                                            #30
                                                            Juhis,

                                                            Beautiful cabinets. The curved sides and integrated top and bottom are simply gorgeous. I hope you enjoy these fantastic speakers.

                                                            What wood is the veneer?
                                                            Mark

                                                            Comment

                                                            • Juhis
                                                              Junior Member
                                                              • Dec 2018
                                                              • 21

                                                              #31
                                                              Originally posted by jacket_fan
                                                              Juhis,

                                                              Beautiful cabinets. The curved sides and integrated top and bottom are simply gorgeous. I hope you enjoy these fantastic speakers.

                                                              What wood is the veneer?
                                                              Thanks for your praise
                                                              I really like this pair still!

                                                              Veneer on front, top and back is 0,6mm thick birch.
                                                              Rounded sides are birch plywood which integrated quite nice with veneer.

                                                              Comment

                                                              • Heli-Tim
                                                                Senior Member
                                                                • Nov 2015
                                                                • 159

                                                                #32
                                                                I'm a little late to the party, but these turned out absolutely beautiful! Perfection!

                                                                Comment

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