SMJ Audio Wavecor Ardent

[Steve Manning]

Crossover Compartment

Here's a few pictures of the crossover compartment. Rather than fight with the small space in the bottom of the original design, let's just make the cabinets 50 lbs heavier.

[Steve Manning]

A test fit up of a bulk of the parts. Today our weather is doing a fine imitation of early summer rather than early spring ..... mid 80's with gobs of humidity. What fit together nicely a few days ago is a little snug today. Nothing a few clamps can't over come though!

[technodanvan]

Looking good Steve! I can't wait to see how you populate that cavernous crossover compartment.

[JonMarsh]

A test fit up of a bulk of the parts. Today our weather is doing a fine imitation of early summer rather than early spring ..... mid 80's with gobs of humidity. What fit together nicely a few days ago is a little snug today. Nothing a few clamps can't over come though!

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This is what ANYONE will call precision wood working... more like machining than wood cutting!

[ergo]

Steve, very nice and 'heavy looking' result.
The MDF and maybe even outer ply layers seem thicker than Jon's original plans. Does it mean the box will be x% bigger in each direction?

[theSven]

My back is hurting now thinking about having to lift or move the cabinet. I would definitely be investing in future dollys to move these towers around. Awesome work Steve.

[Steve Manning]

Steve, very nice and 'heavy looking' result.
The MDF and maybe even outer ply layers seem thicker than Jon's original plans. Does it mean the box will be x% bigger in each direction?

Thanks Ergo ..... good eye, yep, the mdf layer is thicker. Since I had 3/4" cabinet grade mdf on hand I went with that rather than going out and find 1/2" thick stuff. The Baltic Birch is the same thickness though .... unfortunately of varying thicknesses though, making fit up a pain. There will be a 1/8" hdf skin on the outside as well prior to finishing.

Not having the crossovers in the bottom of the cabinet made up for pretty much all of the diminished volume though.

[Steve Manning]

My back is hurting now thinking about having to lift or move the cabinet. I would definitely be investing in future dollys to move these towers around. Awesome work Steve.

Thanks Sven, yep, I'm already grunting moving stuff around. Finishing is going to be a real joy once the baffles are attached. 8O

[Mikerodrig27]

Are the outer width and height dimensions the same and the internal cavity is just deeper to account for the volume loss due to the thicker wood?

[Steve Manning]

Are the outer width and height dimensions the same and the internal cavity is just deeper to account for the volume loss due to the thicker wood?

Yes ..... the baffles had already been made awhile back so the cabinets have to fit them anyway. Of course, it's never really a good idea to change those numbers anyway. With putting the crossovers in the rear of the cabinet any additional volume could be easily made up along with that change as well.

[Mikerodrig27]

Nice. Those are some extremely stout cabinets. I was thinking with this high end of a design and drivers, the baffle dimensions has to be critical.

[Steve Manning]

A bit of an update after some time off due to a death in the family ..... life does not care about schedules even on a good day it seems.

These cabinets are a bit of a puzzle in that they need to be assembled in a certain order so you don't back yourself into a corner. As such, some wiring and dampening material need to be installed prior to gluing too many pieces together or you block access.

Inside the crossover compartment . Building some feed through's for internal wiring.






Some Sonic Barrier installation.

[JonMarsh]

My back is hurting now thinking about having to lift or move the cabinet. I would definitely be investing in future dollys to move these towers around. Awesome work Steve.

You wouldn't believe how many furniture and appliance dollies I own... I lost count ages ago!

[technodanvan]

A bit of an update after some time off due to a death in the family ..... life does not care about schedules even on a good day it seems.

I'm sorry to hear that Steve. As much as I love to see progress take the time you need. This is all temporary anyway, as much as we'd like to believe otherwise.

[Steve Manning]

I'm sorry to hear that Steve. As much as I love to see progress take the time you need. This is all temporary anyway, as much as we'd like to believe otherwise.

Thanks Danny .....

[Steve Manning]

Assembly continues with internal wiring going in prior to the sides being glued in place.

[theSven]

Is that 12 gauge wiring your using Steve?

[Steve Manning]

Is that 12 gauge wiring your using Steve?

Yes it is .....

[technodanvan]

Are you using a lock washer on those pass through connections? I'd hate for one to come loose in a few years since they look very inaccessible.

[Steve Manning]

Are you using a lock washer on those pass through connections? I'd hate for one to come loose in a few years since they look very inaccessible.

That's an idea that has been under consideration in addition to the Lock Tite that I've already used. I think I'll be following Jon's more is better approach. :W

[technodanvan]

Lock Tite is pretty good stuff, probably don't need any more than that....but I like your style.

[Steve Manning]

Lock Tite is pretty good stuff, probably don't need any more than that....but I like your style.

Don't worry Danny, I stopped by Lowes this afternoon and picked up some lock nuts. Now everything is backed up with those.

[Bear]

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I always tell my account teams the old maxim: "'Good artists create. Great artist its steal.' And that I aim to be a great artist." So, in that vein...

Where are you sourcing the gold-plated(?) nuts and screws? Is that another McMaster find? I've been challenged to find these types of what I'd professionally call these "popcorn and peanuts" style parts at something that isn't a ridiculous markup. I understand why small things like this have large per unit prices when sold in small quantities, but I'd just as soon pay the same (or slightly higher) for the full box and have a bunch sitting in inventory.

I think I can find a spot over there... No, that's got a stack of Woofers. Maybe over there? No, that's the big bag of wool. Hmmm....

On a more serious note, my sympathies on your loss.

[Steve Manning]

I always tell my account teams the old maxim: "'Good artists create. Great artist its steal.' And that I aim to be a great artist." So, in that vein...

Where are you sourcing the gold-plated(?) nuts and screws? Is that another McMaster find? I've been challenged to find these types of what I'd professionally call these "popcorn and peanuts" style parts at something that isn't a ridiculous markup. I understand why small things like this have large per unit prices when sold in small quantities, but I'd just as soon pay the same (or slightly higher) for the full box and have a bunch sitting in inventory.

I think I can find a spot over there... No, that's got a stack of Woofers. Maybe over there? No, that's the big bag of wool. Hmmm....

On a more serious note, my sympathies on your loss.

Thanks Bear .......

These are actually not gold plated, their solid brass. I was looking for solid copper for the threaded rod and nuts, but I was not having a lot of luck. As you guessed McMaster Carr came to the rescue and I was able to get 12" long threaded rod which I cut to required length of 3", nuts and washers. Initially I had thought of rhodium plated copper binding posts (Cardas) but figured Danny might have a heart attack over what that would cost!.

So this was my non-magnetic solution ..... not the ultimate conductor but I think they should get the job done.

[technodanvan]

Yeah, Cardas would have been pretty and all, but given it's inside the cabinet away from view I can't see going to that expense. Unless maybe we were using silver wire or something crazy!

[Steve Manning]

Starting to look like actual speakers. Skinning with HDF is next on the agenda.

[JonMarsh]

These are coming along very nicely, Steve. Will you veneer them, too? Or is Danny going to get in on the action?

[theSven]

I’m excited to see the purple get added to these cabinets! Great craftsmanship as always Steve!

[Steve Manning]

These are coming along very nicely, Steve. Will you veneer them, too? Or is Danny going to get in on the action?

No veneer for these guys ..... the baffles and stands will be clear finish on the bamboo and the rest will be colored white. Of course there will be a sliver of purple heart separating the baffle and main cabinet as an accent. Yours truly will be doing that. Danny gets to try and lift them and carry them home. 8O

[Steve Manning]

I’m excited to see the purple get added to these cabinets! Great craftsmanship as always Steve!

Thanks Sven ...... yeah that's going to be cool to see.

[JonMarsh]

No veneer for these guys ..... the baffles and stands will be clear finish on the bamboo and the rest will be colored white. Of course there will be a sliver of purple heart separating the baffle and main cabinet as an accent. Yours truly will be doing that. Danny gets to try and lift them and carry them home. 8O

Hope he's got a bit of a workout regimen going to get ready...

[technodanvan]

Hope he's got a bit of a workout regimen going to get ready...

Interestingly, I actually started going back to the gym about a month ago (once I was vaccinated). I might be ready when the time comes.

Maybe. 8O

[Steve Manning]

Adding a little more weight to things.

Started skinning the cabinets, first one is done and 2/3 through the second.

Did a fit up of the 2nd baffle and found it was in a lot better shape than the first one, as in mostly flat. Clamps with moderate pressure made for a nice fit up.












My biggest concern for this was having to make the cabinets fit the existing baffles. With 3 layers of material getting a good fit I was pleasantly surprised that the height was right on and the width was <1/32". A little sanding and it should be good to go.

[JonMarsh]

Great workmanship from the king of precision!


;x( ;x(


And these are so much more sensible than what I've been working on this weekend...

[technodanvan]

I mean, I guess <1/32" is pretty good. 8O

[JonMarsh]

I mean, I guess <1/32" is pretty good. 8O

well, those kinds of numbers make some people faint... a guy in Singapore about had a heart attack when I suggested 1/64" of an inch cutting precision for fossilized laminated bamboo ply for a shop built set of Isiris cabinets. Just come down to, how much do you want to be fudging and sanding? And since I'm not the woodworker, but the wires and sparks guy, anything I can do, others can do better.

[technodanvan]

Man, I'd be thrilled if I could get everything within 1/32" on any of my projects. I'm pretty sure it's the user at this point, and I'm pretty sure it's mostly a lack of patience.

[Steve Manning]

Man, I'd be thrilled if I could get everything within 1/32" on any of my projects. I'm pretty sure it's the user at this point, and I'm pretty sure it's mostly a lack of patience.

Thing is though, you have to remember your working with wood .... if you get lucky and get it dead on, it might not stay there. Case in point your one baffle that warped, I had to do a skim cut on the back of it today on the CNC so it would fit flat. My hand planing attempt was not good enough that I did earlier.

[Carl V]

Thing is though, you have to remember your working with wood .... if you get lucky and get it dead on, it might not stay there. Case in point your one baffle that warped, I had to do a skim cut on the back of it today on the CNC so it would fit flat. My hand planing attempt was not good enough that I did earlier.

a Finish carpenter friend of mine, has to go over this wood concept with many home owners/ remodeling. I've shown him some of my speakers and other projects.
And he usually zeros in on technique oversights of mine. At the end of the day can you see the problem form 3' away? After two years in a Kitchen can you really expect it to look the same
as day one?

[JonMarsh]

All very realistic points... OTOH, I'm hoping the granite counter I spec'd today looks and dimensions pretty much the same two years from now!

[theSven]

I got to see Dannys cabinets today when I stopped over at Steves. That is ONE SOLID cabinet! The purpleheart wood was really cool to see too. I didn't realize it was actually wood. I thought it was purple plexi to represent a purple heart, but Steve got me correct on that one. Anyways I just wanted to share that I got to see this cabinets and I know they are going to look amazing once Steve gets them painted. Speaking of which I need to see how much black lacquer I have left...

[JonMarsh]

I’m going to try to persuade Steve to get some good pics with his relatively new 4/3 format camera before letting these go to their rightful owner. We need to have them for the archives…

[technodanvan]

Glad to see someone is keeping an eye on Steve!

Purpleheart is pretty cool, just have to be careful with direct sunlight as it'll change color. My wife loves it, so I figured adding a touch to these wouldn't hurt!

I’m going to try to persuade Steve to get some good pics with his relatively new 4/3 format camera before letting these go to their rightful owner. We need to have them for the archives…

If he misses it, I just purchased a pretty nice camera for my wife. I want to say Steve's living room looks nicer than mine though.

[Steve Manning]

Glad to see someone is keeping an eye on Steve!

Purpleheart is pretty cool, just have to be careful with direct sunlight as it'll change color. My wife loves it, so I figured adding a touch to these wouldn't hurt!



If he misses it, I just purchased a pretty nice camera for my wife. I want to say Steve's living room looks nicer than mine though.

My first time working with purpleheart. I thought bamboo was hard, this stuff has ~ twice the Janka hardness. I've been laminating up the crossover boards (.25" hdf + .25" purpleheart) and did a rough sand with 50 grit paper with an electric sander ...... no scratch marks, just a little dust. 8O

My plan is to do photos. Picked up some lights and a new tripod ..... hopefully I get something useful out of it.

[technodanvan]

Are you going to be painting the crossover compartment?