Building Trio of Wedgehorn 10s

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Bruce Weldy
Posts: 8566
Joined: Fri Nov 27, 2009 11:37 am
Location: New Braunfels, TX

Building Trio of Wedgehorn 10s

#1 Post by Bruce Weldy »

Building these to replace Yamaha SM15Vs for monitors. The Yamahas are fine, but heavy. I'm hoping the WH10 will be much lighter....

The panels were all cut a few weeks ago when I was cutting the OT12s that were just finished. Had a few easy bevel cuts to finish up, along with braces, baffle, and strips for attaching the covers.

After cutting the hole in the baffle, I traced the outline of the speaker ring on it and knocked off the corners with a jigsaw.
WH10 Build 002 small.JPG
Then I used double-sided tape to attach the speaker ring and used a router with a bottom bearing to trim to size.
WH10 Build 004 small.JPG
Here's what three stacks of WH10 parts look like...
WH10 Build 008 small.JPG
Time to start gluing 'em up......

6 - T39 3012LF
4 - OT12 2512
1 - T24
1 - SLA Pro
2 - XF210


"A system with a few knobs set up by someone who knows what they are doing is always better than one with a lot of knobs set up by someone who doesn't."

Bruce Weldy
Posts: 8566
Joined: Fri Nov 27, 2009 11:37 am
Location: New Braunfels, TX

Re: Building Trio of Wedgehorn 10s

#2 Post by Bruce Weldy »

Started assembly this morning...

Used the "W" jogs to hold the braces perpendicular while gluing and nailing.
WH10 Build 010 small.JPG
Braces all done.....the picture makes it look like night. It was taken at 10am this morning. Big storm coming through central Texas. Really dark, wind, rain, and maybe hail.....I love it! We're in a drought and can use the rain - probably won't be enough though.
WH10 Build 011 small.JPG
More in a little while....

6 - T39 3012LF
4 - OT12 2512
1 - T24
1 - SLA Pro
2 - XF210


"A system with a few knobs set up by someone who knows what they are doing is always better than one with a lot of knobs set up by someone who doesn't."

Bruce Weldy
Posts: 8566
Joined: Fri Nov 27, 2009 11:37 am
Location: New Braunfels, TX

Re: Building Trio of Wedgehorn 10s

#3 Post by Bruce Weldy »

One shell done....two to go.
WH10 Build 013 small.JPG
WH10 Build 015 small.JPG

6 - T39 3012LF
4 - OT12 2512
1 - T24
1 - SLA Pro
2 - XF210


"A system with a few knobs set up by someone who knows what they are doing is always better than one with a lot of knobs set up by someone who doesn't."

Bruce Weldy
Posts: 8566
Joined: Fri Nov 27, 2009 11:37 am
Location: New Braunfels, TX

Re: Building Trio of Wedgehorn 10s

#4 Post by Bruce Weldy »

Three shells done.....cut the parts for the handhold pockets.

Probably won't get to touch 'em again until Monday. Three day golf tournament starts tomorrow. It'd cost less and be less frustrating to stay home and work on monitors.....oh well.....
WH10 Build 017 small.JPG

6 - T39 3012LF
4 - OT12 2512
1 - T24
1 - SLA Pro
2 - XF210


"A system with a few knobs set up by someone who knows what they are doing is always better than one with a lot of knobs set up by someone who doesn't."

Lastcat
Posts: 232
Joined: Tue Aug 17, 2010 12:33 pm
Location: Washington State
Contact:

Re: Building Trio of Wedgehorn 10s

#5 Post by Lastcat »

Thats looking good Bruce, keeper coming. :clap:
Currently Built:
4 T39 24" 3012LF
4 WH10 2510
4 DR200 Pro 8a
4 DR250 2510
**************

Bruce Weldy
Posts: 8566
Joined: Fri Nov 27, 2009 11:37 am
Location: New Braunfels, TX

Re: Building Trio of Wedgehorn 10s

#6 Post by Bruce Weldy »

Back at it....

Built the boxes for the handholds and installed them last night.
WH10 Build 022 small.JPG
Cut the ports in the horn sides with a hole saw then used a router to round over the edges.
WH10 Build 019 small.JPG
Next up - opening up the handholds from the outside. First, drilling access holes.
WH10 Build 020 small.JPG

6 - T39 3012LF
4 - OT12 2512
1 - T24
1 - SLA Pro
2 - XF210


"A system with a few knobs set up by someone who knows what they are doing is always better than one with a lot of knobs set up by someone who doesn't."

Bruce Weldy
Posts: 8566
Joined: Fri Nov 27, 2009 11:37 am
Location: New Braunfels, TX

Re: Building Trio of Wedgehorn 10s

#7 Post by Bruce Weldy »

I used a jig saw to open the holes bigger. I didn't want to try and hog out all that material with the router.
WH10 Build 021 small.JPG
Used the router with a bottom bearing bit the flush up the opening with the inside box.
WH10 Build 025 small.JPG
Then, finished up by rounding over the edges.
WH10 Build 023 small.JPG

6 - T39 3012LF
4 - OT12 2512
1 - T24
1 - SLA Pro
2 - XF210


"A system with a few knobs set up by someone who knows what they are doing is always better than one with a lot of knobs set up by someone who doesn't."

Bruce Weldy
Posts: 8566
Joined: Fri Nov 27, 2009 11:37 am
Location: New Braunfels, TX

Re: Building Trio of Wedgehorn 10s

#8 Post by Bruce Weldy »

Went off the reservation here a bit....

Decided to put all four horn sides together before attaching the baffle. Attached the two sides with the horn jig as per the plans, then used some 2 1/2" spacers - along with marking the horn bottom and top so they would line up correctly.
WH10 Build 032 small.JPG
Then, I removed the jig and used the spacers along with a clamp to keep the top exactly the right width apart. The reason I did this is that the jig is hard to align so that the width is exactly right. I just made sure that the bottom panel was correct, then used the spacer for the top.
WH10 Build 029 small.JPG
This created a really nice flat surface to attach the baffle.
WH10 Build 027 small.JPG
Last edited by Bruce Weldy on Wed May 25, 2011 11:02 pm, edited 1 time in total.

6 - T39 3012LF
4 - OT12 2512
1 - T24
1 - SLA Pro
2 - XF210


"A system with a few knobs set up by someone who knows what they are doing is always better than one with a lot of knobs set up by someone who doesn't."

Bruce Weldy
Posts: 8566
Joined: Fri Nov 27, 2009 11:37 am
Location: New Braunfels, TX

Re: Building Trio of Wedgehorn 10s

#9 Post by Bruce Weldy »

Next, I put the pet screen on the baffle instead of the horn. This made it easy to stretch and keep the staples out of the way.
WH10 Build 030 small.JPG
Then the baffle was glued and nailed in place along with the spacer ring.
WH10 Build 031 small.JPG
Next up is fitting the horn to the shells with a setback for the grills.

6 - T39 3012LF
4 - OT12 2512
1 - T24
1 - SLA Pro
2 - XF210


"A system with a few knobs set up by someone who knows what they are doing is always better than one with a lot of knobs set up by someone who doesn't."

UROK

Re: Building Trio of Wedgehorn 10s

#10 Post by UROK »

:clap:

Bruce Weldy
Posts: 8566
Joined: Fri Nov 27, 2009 11:37 am
Location: New Braunfels, TX

Re: Building Trio of Wedgehorn 10s

#11 Post by Bruce Weldy »

Man, trimming the horn to fit in the shell is very tedious. Finally got it to fit and because I'm putting grills on, I've got to cut the horn back some.

I ran screws through the shell to hold the horn in place. Used the plies as my measuring device...left 6 sticking out.
WH10 Build 034 small.JPG
Then used a router bit with a top bearing to trim the horn flush with the shell. One side left to go....
WH10 Build 035 small.JPG
Now here's the real problem....there is no room to get screws back there to hold the driver. Working with Leland for a fix. Looks like it will have to be T-nuts as the recex screws just ain't gonna fit.
WH10 Build 036 small.JPG

6 - T39 3012LF
4 - OT12 2512
1 - T24
1 - SLA Pro
2 - XF210


"A system with a few knobs set up by someone who knows what they are doing is always better than one with a lot of knobs set up by someone who doesn't."

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Bill Fitzmaurice
Site Admin
Posts: 28955
Joined: Tue May 02, 2006 5:59 pm

Re: Building Trio of Wedgehorn 10s

#12 Post by Bill Fitzmaurice »

Bruce Weldy wrote:
Now here's the real problem....there is no room to get screws back there to hold the driver.
There is, but you have to pre-drill pilots before assembling the cab, and use a right-angle driver or 1/4" socket wrench to get at them. What works best is a 1/4" socket on a u-joint at the end of a long extension on the ratchet.

Bruce Weldy
Posts: 8566
Joined: Fri Nov 27, 2009 11:37 am
Location: New Braunfels, TX

Re: Building Trio of Wedgehorn 10s

#13 Post by Bruce Weldy »

Bill Fitzmaurice wrote:
Bruce Weldy wrote:
Now here's the real problem....there is no room to get screws back there to hold the driver.
There is, but you have to pre-drill pilots before assembling the cab, and use a right-angle driver or 1/4" socket wrench to get at them. What works best is a 1/4" socket on a u-joint at the end of a long extension on the ratchet.
Do you mean to do that with a square head bit and use the recex screws? Or, go with t-nuts?

6 - T39 3012LF
4 - OT12 2512
1 - T24
1 - SLA Pro
2 - XF210


"A system with a few knobs set up by someone who knows what they are doing is always better than one with a lot of knobs set up by someone who doesn't."

User avatar
Bill Fitzmaurice
Site Admin
Posts: 28955
Joined: Tue May 02, 2006 5:59 pm

Re: Building Trio of Wedgehorn 10s

#14 Post by Bill Fitzmaurice »

Bruce Weldy wrote:
Bill Fitzmaurice wrote:
Bruce Weldy wrote:
Now here's the real problem....there is no room to get screws back there to hold the driver.
There is, but you have to pre-drill pilots before assembling the cab, and use a right-angle driver or 1/4" socket wrench to get at them. What works best is a 1/4" socket on a u-joint at the end of a long extension on the ratchet.
Do you mean to do that with a square head bit and use the recex screws? Or, go with t-nuts?
Screws.

Bruce Weldy
Posts: 8566
Joined: Fri Nov 27, 2009 11:37 am
Location: New Braunfels, TX

Re: Building Trio of Wedgehorn 10s

#15 Post by Bruce Weldy »

I always say you can't have too many tools....but, I'm beginning to wonder. Drove away from the house to go find a long extension and a u-joint for my 1/4" drive. A couple of blocks away, I thought hmmmmm....maybe I'd better do some checking before I go buy something.

Sure enough, I had a long extension and a u-joint in a little case that I had gotten from my dad when he died....I guess I ought to do an inventory some day. I'm always coming across stuff that I forgot that I have.

So, to make a short story long - I think I can make the recex screws work. I did drill the holes at an angle to make it a little easier to get back in there.

Now to get the horns glued in.

6 - T39 3012LF
4 - OT12 2512
1 - T24
1 - SLA Pro
2 - XF210


"A system with a few knobs set up by someone who knows what they are doing is always better than one with a lot of knobs set up by someone who doesn't."

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