My 3rd BFM horn.... the T60

[subharmonic]

It seems like each build is getting larger and heavier (2x T-39 20" then a THT 24.5"), of course my next plans are some THTLP so it will continue. I really wasn't planning on this build but a deal on some Lab 15 s, 80 lbs of scrap copper needed to be recycled, and expectant baby next spring made me jump on this while I have time, money and sanity.

The build days are not consistent but thought I would lay out how it started and is progressing. I have been racing against the weather as I don't have a heated garage, this is never a good thing to do with these builds. Decided to go BB on the outside except panel 10 and acuaro for the guts.

Day 1
Got 2 sheets 5x5 BB and ripped them down with a guide board system. Made all the lines per the plan and made access hole for driver. Best access hole cut yet! I used BB to draw lines with full intention of using acuaro ply for inside panels, the thickness is a little different. More time should have been spent on the ripping cuts too as the they were a bit off/wobbly.

Day 2
After spending way too long trying to find some decent 8x4 sheets at Menards, I had to settle by picking the 2 best out of the maybe pile. What a workout, moved a dozen sheet twice. At least I got the "pump" going as Arnie says it

Had a friend of mine rip 48"x26" panels as he is a cabinet maker. What a life saver as it went quick, effortless and precise cuts. Brought them all home and got panels 1 and 2 up. Panel 1 is 1/2" too short according to the lines on side panel, panel 6 will have to make up the difference, need to measure these things 1st instead of going by plan...even on 1st panel.

Day 3
Able to get panels 3-5 up with a few known issues at the time, mainly a boat load of time spent on panel 4. Besides my newly acquired tablesaw is a POS and may possibly have a personal grudge against me. Reverting to guide board and 14.4 volt skill saw. Joint 2&4 are needing some PL love to fill the angle being open a bit. Also the tip at joint 3&4 is a little short but can't see that being a huge issue

Day 4
Panel 6 and braces go up with little issue. I am using lower grade 1/2" ply for bracing, had it sitting around the garage. Then came panel 7. This was a nightmare, just could not get the angles right, something was always wrong. Panel ended up a bit short at the top of the mouth. PL fills the angle gaps again. My belt sander made all the difference in the world on this. It was time to drink when this was done

Day 5
Panel 8 was a breeze except the bracing. I installed what I thought was a nice tight fit but not too tight for the braces. I had a ton of issues getting panel 9 in. Day 5 started to haunt me on day 6. Put wire #1 in to the mouth.

Day 6
When I tried to put in panel 10 the corner was about 1/2" off at the "top" where they meet. It turned out the braces pushed everything out a little. 3-5 clamps helped gradually pull the corner in, brad nailed everything together at the 8&9 corner but left my clamps on for a couple days. Got my wire #2 in to the last reflector area. Panel 10 braced and ready to go.

By luck I learned a great technique for finding air leaks prior to closing up the horn. Can't remember why but had a bright flashlight looking down some of the empty chambers and noticed I could see it in the adjacent part of the throat, UH OH. It was mainly on the cheated angles. Well a lot of choice words and lots of PL later I am glad I caught those issues. I just caulked the lines with PL and my finger until no light came through anymore. Now I am second guessing my other builds, however I was unable to ever find a leak in any of them doing the stethoscope method when they were done.

Day 7
Put in last panel and 1st reflector. Caulked the reflector with PL as light came through again. I also started to build the mouth and last part of the throat bracing. I had been making a lot of my cuts using a 4x8 piece of styrofoam for insulation. So since I already had a sacrificial top, I just screwed the braces down part by part to it, gluing them as I went. Worked like a charm, nice and straight. They glued down a bit but broke loose and sanding them took care of everything.

I painted the last part the throat with some left over dark deck paint. Unfortunately even though I thought about it I started painting the wrong side of the finishing side panel...doooh. So I guess I will be finishing the outside of the built too. Though I would wait until it was done to decide if that was going to happen.

Day 8
Put in last reflector, last throat braces in. Painted the mouth and braces for the mouth. Hopefully I will get my package from LeLand tomorrow so I have my casters and handle holes to cut out. I have a multi tool so cutting them out after should not be an issue.

Getting close to done! I am on the home stretch, usually the hardest part. Prelims are telling me some major clamping will be in order to make this sucker close up right. I will try to get some pics up soon, but it is a little late for me to at the moment. Hopefully some one can learn from the pitfalls I have encountered.

[mems]

Excellent work. I too needed to use a flashlight to view inside of a reflector on my T30 the other day and figured out the same thing that you did. I did see some light protruding through and tried my best to PL those areas correctly. I'm not sure if i got to all of it that I thought might be a problem but figured I would run some air with the compressor along that line now that it has dried and make sure there are no leaks. This combo "trick" of light while installing and air after each panel has dried, I've been using all along and it works great, just forgot to post about it as you did. Good looking out.

[SeisTres]

Yeah, although I've always done this with all my cabs, I had forgotten to post it on here for others. As all my cabs have always been relatively small, once everything is dry, I simply hold it up to the light buld. Extremely easy to spot. I guess this is one of the reason that even though they're really ugly, I've only gotten about two airleaks in all of my sub builds.

[subharmonic]

Excellent work. I too needed to use a flashlight to view inside of a reflector on my T30 the other day and figured out the same thing that you did. I did see some light protruding through and tried my best to PL those areas correctly. I'm not sure if i got to all of it that I thought might be a problem but figured I would run some air with the compressor along that line now that it has dried and make sure there are no leaks. This combo "trick" of light while installing and air after each panel has dried, I've been using all along and it works great, just forgot to post about it as you did. Good looking out.

I will have to try the compressed air thing. Seems that sometimes the light is hard to see unless it is really dark. I have put moving blankets over me to see the light. Compressed air seems like a much easier thing in the day time after initial "fixes" have been made.

+1 to mems

[subharmonic]

Found more light. Geesh, it is like the old cartoons with the guy plugging holes with his fingers while the boat is sinking...he plugs two and two more pop up. Hopefully pics by this weekend.

Day 9

Mouth braces in. Some paint and I will be ready to put the other side on. Unfortunately have to go out of town for a day or two and nasty weather is coming in. LeLands package came in so I have casters, corners and handles to add to it when the dust settles.

[Bryson]

Are leaks pretty common? I built my first T24 and never used the flashlight. I assumed with the precision of the cuts (I'm no carpenter but, they were tight) and the expansion of the PL that there was no way there would be leaks. Now you've got me nervous!

Where you are seeing light, are these areas that would visibly concern you?

[mems]

My only time i had an issue was the last reflector of my T30. The cut was supposed to be 50 degrees and i couldnt get it where i needed it. I figured the PL would make up for it but for me it was all in making sure most of the time. These have been my first builds so I just wanted to make completely sure that they were no air leaks. For the time it takes to check quickly if there are leaks after each panel dries, literally 30 seconds, is waaaaaay better than having to pull a panel off after PL'ing it. Been there done that with just a crossover plate and it wasnt fun at all.

[subharmonic]

I have had a huge issue on this build. I remember on my 1st titan build actually noticing daylight at some point so I caulked it with PL. So far all my builds have been seemingly sealed properly, if they aren't performing up to their expectations I would be shocked, than I am in for a huge treat on this guy. I haven't been able to detect leaks when I was done on my other builds.


HOWEVER...for whatever reason on this build I am plagued by them. It may be since I was getting arrogant with my PL and using less than normal. I guarantee you when I get ready to put the last side on I will use PL on top of PL with a side of PL.

[Radian]

I guarantee you when I get ready to put the last side on I will use PL on top of PL with a side of PL.

[Tom Smit]

I guarantee you when I get ready to put the last side on I will use PL on top of PL with a side of PL.

+2

[subharmonic]

Does anyone have a good shot we can call the "PL"?

I am thinking it would along the lines of a "gorrilla fart", "cement mixer" or "brain tumor".

We all know how nasty this stuff is when it gets out of hand.

[Radian]

Diaper dollop

[Drey Chennells]

Diaper dollop

[subharmonic]

Diaper dollop

What the heck is that? I tried finding it online but no recipe found. I found Diaper Stripes and Diarrhea Bomb recipes on drinksmixer.com. There are some non PG drinks on that site, holy cow!

That gives me an idea, maybe I can incorporate something into the mouth of the T60 to mix drinks? Besides dubstep.

[subharmonic]

Day 9

Bought pipe for pipe clamps as my current arsenal of clamps only goes to 48", guess what build was on my mind when I bought them. I was able to get the sub off the workbench onto some buckets. It was a necessary move since I wasn't smart enough to buy some smaller black pipe and extend it with couplings so (they jumped from 60" to 10' in size). Now my pipe is wider than my garage, so I had to make the whole thing turn 90 degrees and brought it down to a more workable height. Good news is I had a successful test clamp bringing the whole cab into alignment.

I had some throat bracing loose in a spot on the bottom of the throat and on a cross brace touching the vertical. I put some gorilla glue on it and will let it sit to morning. Then my friends the really fun starts. The final side will go on. If you haven't invested in PL stock yet you may want to as there will be a national shortage of it once I line all my panels.

I will try to remember to take a picture of it with the side open standing next to it. I had that moment of clarity when I got it off the bench and was standing next to it. This thing is like Noahs Ark, maybe I should name it like I do my vehicles. Elvira may get a bit jealous.