SMJ ET CCTT Build

[JonMarsh]

Progress is good to see, and a very good thing in general!

[theSven]

Great to see the baffle coming together and I'm excited about the gasket for this build!

[Steve Manning]

Progress continued today and I was able to finish the machining of the baffle.











Some rough sanding and threaded inserts are next on the agenda.

[JonMarsh]

Looking very good Steve! Doubly makes me wish I wasn't tied up with logistics pretty much all month!

[technodanvan]

Looking great as always Steve! What's the plan for the gasket? Separate pieces or did you find some kind of liquid rubber that would form a one piece solution?

[Steve Manning]

Thanks gents ... Danny I found a 1/4" dia. foam rubber gasket on Amazon that I think will do the trick. The O-ring groove is .150" deep so in the test sample I did, it seems to offer a nice bit of compression for sealing. You just have to cut the cord to length and the super glue the ends together and now you have a solid o-ring. Believe it or not that's how it's done in the world of vacuum systems, unless you get pre-made units made to size.

[Steve Manning]

As Jon is fond of saying about slow work taking time, some progress is being made.

All the major parts are fabricated and initial fit up done.









This is one of 4 brackets that hold the baffle in place.

[Steve Manning]

Some tweaking of the baffle needed to be done to get things aligned a little better. Then drivers were installed to check fit. These pictures are rather deceptive ..... those woofers are 8.7" in diameter!









The last remaining item is determine the orientation of the binding post plate and machine some pockets for that to recess in. Then it's on to the crossover.

[JonMarsh]

It's all about scale, and making it "look normal" because of how everything is scaled together!

[JonMarsh]

How does that old Campbell soup commercial go?

"Mmm, mmm, good!"

[JonMarsh]

Some tweaking of the baffle needed to be done to get things aligned a little better. Then drivers were installed to check fit. These pictures are rather deceptive ..... those woofers are 8.7" in diameter!

Yeah, the actual size relative to what the image tells you doesn't quite match up.

Like, seeing pictures online of the Cyber Truck, I have in mind an idea of how big it is, but because of the proportions, including wheels, it's starting when I'm in CA and see several of them and realize how much bigger they actually are. Imagine a Civic Type R, or any version, but then seeing a car that's like 30-40% bigger, but exactly the same proportions.

These are not your father's center channel speaker... (but then, my father didn't have any kind of speakers or music system!)

[theSven]

Great updates to read tonight now that I'm back in the USA for 13 days 😂. Busy trip that I didn't have much time for getting online or keeping up with much else other than my inbox at work. Looking forward to picking this up later this summer for a fall project to work on!

[Steve Manning]

A quick update .... Machined a pocket for the binding post plate.





Binding posts installed.



Base section components epoxied in place on the first circuit board.

[technodanvan]

What binding posts are those? They don't look like Viborg.

Also, did you mention somewhere that the rubber (or was it cork?) between wood slats is no longer necessary?

[Steve Manning]

What binding posts are those? They don't look like Viborg.

Also, did you mention somewhere that the rubber (or was it cork?) between wood slats is no longer necessary?

Those are ViaBlue T6S binding posts. As I recall the Viborg's were out of stock at the time and these prices in between them and something like Cardas.

We opted not to go with the spacers on this build and as such just glued the ribs together. The material we had used was a combination of cork and rubber though.

[theSven]

Exciting to see the crossover boards starting. It's an art form in itself.

[Steve Manning]

Well I had a minor set back on the first crossover board. Of course I'm going to blame it on Jon, he is, after all the one that picked these soda can sized caps!



I had just a couple of parts left to place and realized I might have a problem.



Said big cap and the woofer magnet were going to compete for the same volume of air. This was confirmed and now the last 2" of the board has become an exclusion zone ..... so modifications have begun. Tis always something!

[theSven]

How much does that cap weigh? I've never seen a cap that huge...

[JonMarsh]

How much does that cap weigh? I've never seen a cap that huge...

Ah, my lad, but you have lead a sheltered life!

[JonMarsh]

Just a mere 200uF!

[Steve Manning]

Those caps weigh in at .7 lbs, not crazy, but since there are 4 of them it adds up.

[Steve Manning]

Well life has been it's usual self and throwing many obstacles in the way of my plans. Finally I've gotten back on track, at least for now.

Those not so little caps helped contribute to the obstacle path. What I had planed for securing the boards inside of the cabinet, just didn't work. There was not enough room to reach in and get screws in the required locations. Attempt number two, unfortunately only worked slightly better, but still failed. I ended coming up with a completely different idea than originally planed that worked out nicely.

Boards finally installed and cabinet mostly wired. The top board as pictured is for the tweeter and woofers and the bottom board the midrange.

[JonMarsh]

Yeah, it's a brute of a design... pretty fun to see the "pretty" version coming together!

[Steve Manning]

Things moved on to driver prep for installation.






Also got the binding posts connected.

[theSven]

The photos are not loading for this one. I think you need to re-upload the photos.

[Steve Manning]

I had an error during upload of one picture, but otherwise things looked OK. I just deleted and reloaded the pictures.

[Steve Manning]

That then left the big question ...... will it make music? An appropriate test disc was selected and fingers crossed .....





Houston we have lift off!

Tag Sven .... your up!

[JonMarsh]

Very appropriate disk, considering the artists I've been adding to my collection the last three years, and a nice choice for these speakers. As you mentioned in your message yesterday, they should have some punch with this program material!

[theSven]

Really looking forward to getting this back home to start finishing it and begin using it. Fantastic work Steve!

[Steve Manning]

Well in the spirit of Jon's Sunday Funday ..... I decided to see how much this beast of a center channel weighs. Any guesses from the audience ?

[Hdale85]

45lbs

[Steve Manning]

45lbs

Not a bad guess but unfortunately it's a fair bit more.

[theSven]

Not a bad guess but unfortunately it's a fair bit more.

98 lbs?

[Steve Manning]

98 lbs?

Closer .....

[Hdale85]

118lbs

[JonMarsh]

Ya know, I don't think that will ship USPS...

Now, this does bring up a few other options I was going to throw into the discussion- like a C-3PO build for the center, or a short tower version for stereo mains. There are about 40 of the Tangband Coax drivers in stock at PE last time I checked with them.

They could be combined with any number of LF configurations and levels adjusted to match.

[Steve Manning]

Ya know, I don't think that will ship USPS...

Now, this does bring up a few other options I was going to throw into the discussion- like a C-3PO build for the center, or a short tower version for stereo mains. There are about 40 of the Tangband Coax drivers in stock at PE last time I checked with them.

They could be combined with any number of LF configurations and levels adjusted to match.

I was thinking the same for a tower option .....

[Steve Manning]

Yep, I don't think the post office would touch this beasty ..... the weight as it sits is a few ounces over 150 lbs! It might pick up a few more pounds once feet and stuffing are added.

[Hdale85]

Yeah we were kinda talking about options in the other thread, I could possibly go down this Coax path for some towers. Although I couldn't afford those LF drivers lol.

[theSven]

Problem after problem the last 2 weeks! Flights getting cancelled trying to get back to the Northern VA area, computer hard drive (Samsung NVME SSD) dying unexpectedly, and the wifi router deciding it's had enough of working and wanting to break. After getting the last flight out of town last Friday back to VA I didn't have time to rent a car and drove my little car up to Steve Manning to pickup the CC. I had a great morning/afternoon listening to the speaker and catching up with Steve in person. The last time I saw him was in 2021 I think when I picked up the SMJ Ardent D materials. It had been too long. On the plus side Steve now lives a lot closer than before. It's under a 2 hour drive now vs 3+ hours trying to get down South where he previously lived.

Anyhow Steve walked me through taking the speaker apart that way I would know how to get this beast back together. When all the pieces are removed from the cabinet I can man handle the moving of it. I just need to remember to be very careful I don't bump into anything while moving it. This is how the cabinet looked in my little Hyundai Veloster:





The baffle and base plate were in the back seat of the car. The speakers, crossover boards, and hardware were carefully placed in the passenger seat. The drive back home took 20 minutes longer due to traffic. I got to see a new part of Maryland besides visiting Steve that I've never seen. Traffic on the 495 beltway was really bad, thankfully Wayz redirected me through some subdivisions and got me back on 495 by the Potomac river which is the border of MD/VA. Then it's about 5 miles or less to hop onto the express lanes and get away from the traffic.

Upon arrival to the house I unloaded the parts and they have been sitting in the living room now. I have to keep them in sight to not forget about what I need to do.

Now the fun begins to get this project completed and be able to use this new CC in the theater!!!!

[theSven]

This post is long overdue and having horrible hotel internet this weekend was no help. I flew out of town for the last three weeks for a work trip, got home for 2 days and left again for the week to the West coast. That said there will be little to no progress made till sometime in October. I was able to get sanding done and 1 coat or primer on.

I was able to get all the pieces sanded and below are photos from the sanding process:



The portable table setup for sanding



The cabinet on the table. It's a workout lugging this cabinet around. I have to pay careful attention when going through doors that I don't damage any corners.



The tried and true Bosch sander that has been used in the last 2 projects I've done on the site here.



The cabinet turned on the table and sanded.



Sanding the bamboo base of the cabinet.



Sanding the back of the baffle first, and then sanded the front of the baffle.

Next up is the start of painting...

[theSven]

After the sanding of the pieces were done it was paint time! Here are some photos of how the process I started:



Due to the weight and design of the cabinet I decided that I want the cabinet up in position for painting. The bamboo will have a clear coat applied, but until that happens I triple wrapped it in plastic wrap, and put duck tape over the holes where the bolts are used. That way there would be no bleeding or dripping.



I put up plastic on both sides of the garage stall, a fan down at the bottom, and light with bungee cords on the garage lift. The portable table moved into the garage. Do you notice all the primer on the garage? That's from the last 2 builds.



Some of the usual suspects on the table. Steve Manning has gotten me hooked on using the Emtech primer. The primer is water based and the clean up easy. I've used this primer on the last 2 projects and I've been very happy with results! The cabinet on the table. I painted vertically like this at first, then used the base to paint the sides. Lastly a mask to protect the lungs from the vapor when spraying.



Everything is in place and it's time to start spraying some primer!









First coat or primer sprayed on the cabinet.



A close up of the primer while still web after spraying the cabinet.

[theSven]

Continuing from the last post of painting the first coat of primer.



The left side of the cabinet before spraying



The right side of the cabinet before spraying.



The crossover and speakers have been moved to the theater room to keep them out of the way for now. I will assemble the CC in the room due to the size and weight. This is not easily moved after assembly.

[technodanvan]

Man, I don't know how you travel as much as you do. This is looking great, but I'd be antsy to get back to it to finish the job!

[theSven]

It's fun for me. There is an opportunity cost though to get projects done. Thankfully I have Steve to help expedite the projects and all I need to do is paint and assemble.

[theSven]

Sitting around in meetings all day, but this morning I ordered the stuffing that will go into the center channel. I ordered a 5 lbs bag, which is probably more than I need. I can save the rest for later projects.



Last night before I made it to bed I was looking at the spikes. The cheaper option that Steve Manning shared doesn't seen to be available. The website is no longer available. I either have to fork out the cash for ViaBlue or try to find another option.

[technodanvan]

I've already got a thing going with a machinist. I should show him a picture of a ViaBlue and ask what it'd be to make a run of a few sets...

[theSven]

I've already got a thing going with a machinist. I should show him a picture of a ViaBlue and ask what it'd be to make a run of a few sets...

Yes please do. It would be great to get some other options.

I ended up ordering 4 of these brass ones from Eden Sound Audio:

[technodanvan]

That is a big freaking spike! Should go well with your big freaking center channel!

Just sent an email to my guy Troy, asking for a ballpark on a run of 100 spikes and provided a picture of the above, a ViaBlue, and a Dayton spike as examples. I assume we'd also use brass, but if we're serious about this I'd want to do some research as to why that is the material of choice, or if some combination of other materials might be better suited.

Edit: I was hoping this guy would have more spikes in stock but it doesn't seem he's gotten around to getting custom models spun out yet. I do want to try his terminal plates sometime though!

https://www.jfcomponents.com/diy

[theSven]

That is a great link with some pretty cool terminal options!

[JonMarsh]

Continuing from the last post of painting the first coat of primer.



The left side of the cabinet before spraying



The right side of the cabinet before spraying.



The crossover and speakers have been moved to the theater room to keep them out of the way for now. I will assemble the CC in the room due to the size and weight. This is not easily moved after assembly.

That seems to be an "unfortunate hallmark" of some of the more recent designs I've been working on! Like, even reworking my Ardent D's! This reminds me of what I went through setting up backyard paint booth for lacquer for the Kurosawas back in Danville...

[JonMarsh]

Sitting around in meetings all day, but this morning I ordered the stuffing that will go into the center channel. I ordered a 5 lbs bag, which is probably more than I need. I can save the rest for later projects.



Last night before I made it to bed I was looking at the spikes. The cheaper option that Steve Manning shared doesn't seen to be available. The website is no longer available. I either have to fork out the cash for ViaBlue or try to find another option.

It's not easy to stay in business in this industry...