Ken's Family Build

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Ken Lustgarten
Posts: 263
Joined: Mon Jan 04, 2010 9:36 am
Location: Bradley, WV Authorized Builder

Re: Ken's Family Build

#16 Post by Ken Lustgarten »

jswingchun wrote:I guess I was wondering more how you were aligning the cut line to the blade on the bevel cuts. Are you just eyeballing it?
For these cuts only one side has a bevel so I cut the bevel first by eye and then set stops to cut the strips to width. Once you make the first cut or even a dry pass you can use the kerfs in the scrap ply to align the cut. For a bevel on both sides (when making several identical parts) I would make the first cut by eye with the kerf as a guide and then set 2 stops so that the second bevel could be made to finished width. For a single part I would just use the kerf as a guide.

I do have a table saw also but have not had to fire it up for this project. It is true that some parts of this process might be a little faster on the tablesaw but there are other parts that would be much slower or even dangerous so in the end there is really no advantage to the tablesaw but there is a big difference in safety. I have used tablesaws all of my life both professionally and as a hobby without any incident whatsoever, not even a single kickback. As I get older I at least hope that I get smarter and I realize that one day my luck will run out on the tablesaw. I now choose to work safer and the tracksaws (any brand) are a better way to work but it takes time to learn to work and think differently.

Ken Lustgarten
Posts: 263
Joined: Mon Jan 04, 2010 9:36 am
Location: Bradley, WV Authorized Builder

Re: Ken's Family Build

#17 Post by Ken Lustgarten »

Steve wrote:Is that a Shop Smith from out of the past in the background? Mine is in too many pieces to use any more.

Steve
Yes that is a Shopsmith. Mine was made in the late 50's. I completely rebuilt it. All new bearings, spinal, motor, belts, new table system.... It is the equivalent to a brand new machine. I bought the components on sale and sold the original parts on Ebay. The Shopsmith and a good jointer cost me $200. By the time I got done rebuilding it and selling off the old parts I still have less then $1000 in the machine. I have used it a lot while building the DR's. The bandsaw and 12" disk sander have been the most used tools on the Shopsmith for these builds. The disk sander is great while fitting all the smaller pieces. The table and mitre gauge can be set to the desired angles and the pieces can be sanded to fit perfectly.

Ken Lustgarten
Posts: 263
Joined: Mon Jan 04, 2010 9:36 am
Location: Bradley, WV Authorized Builder

Re: Ken's Family Build

#18 Post by Ken Lustgarten »

I made some more progress on the DR's. The DR250's are now caught up to the same place as the 200's. Next I have to make the melded tweeter arrays and test fit before continuing any further. On Saturday I went to pick my family up (12 hour drive) so the weekend was pretty much shot. Now that my family is home from vacation progress will be somewhat slower but I think that I got a great start in a relatively short period of time on the 8 DR's. The most important ones to finish first is the pair of DR250's. They will be needed in 3 weeks for the group that is going on tour.

I will post some more pictures tonight.

Ken Lustgarten
Posts: 263
Joined: Mon Jan 04, 2010 9:36 am
Location: Bradley, WV Authorized Builder

Re: Ken's Family Build

#19 Post by Ken Lustgarten »

Here are a few pictures of the Dr250's. They are a little further along then what the pics show. Hopefully I will get to do a little more after I get home from work tonight. Yard work is piling up again and I also have to finish building a playground for the kids. Not to mention the honey do list which includes building a deck, wire, sheetrock and finish the last bedroom in our house (currently my workshop), build upper kitchen cabinets for one side of our kitchen, install a wood stove. I will be moving my shop out to the garage soon. This house was a complete redo so that's why my tools were inside.

https://picasaweb.google.com/klustgarte ... -Zmfr4D6Bg#

Ken Lustgarten
Posts: 263
Joined: Mon Jan 04, 2010 9:36 am
Location: Bradley, WV Authorized Builder

Re: Ken's Family Build

#20 Post by Ken Lustgarten »

I haven't been able to do any more work until tonight. Last week was the end of school for the college that I work at. There was a Bible Conference which meant that I had to work 4 16 hour days in a row and then graduation was on Saturday which was another long day. I ran sound for all the events and with the various music groups and sound checks I just had no extra time.

I made 2 piezo jigs for gluing up the melded arrays. I figured that 2 jigs would help speed thing up since I am making 6 arrays. The cutting went very smooth. Today I glued up the arrays for the DR250's and 2 flat arrays for the DR200's (2 flat and 4 melded DR200's). I did hit a snag it seems that I have 17 piezos that will not come apart. I did rip one apart to see what the problem was and I found that they are glued together from the factory. This may be an issue in the future if an element needs to be replaced. I am a couple short and need to order some more because I also have 3 Wedgehorns on the horrizon but first the DR's and Titans. Are all the new piezos glued? I am not to happy and these are from the last batch that I ordered a few weeks ago.

https://picasaweb.google.com/klustgarte ... hLeK0d7jIA#

djtrumptight
Posts: 823
Joined: Tue Dec 15, 2009 6:08 pm
Location: Detroit,Michigan

Re: Ken's Family Build

#21 Post by djtrumptight »

Yep,they all come glued now.
Built:
2 Autotuba's MCM 55 2421
8 T48's 24"wide 3015 LF
2 DR 250's melded Deltalite II 2510
2 DR 250's flat Deltalite II 2510
2 SLA HT systems
1 Table Tuba Dayton DCS 255-4
2 T 39's 20" wide 3012 LF
1 T-18 13" wide MCM 55 2421
2 SLA Pro's

SeisTres
Posts: 2688
Joined: Fri Apr 24, 2009 3:53 am
Location: Dallas, tx

Re: Ken's Family Build

#22 Post by SeisTres »

djtrumptight wrote:Yep,they all come glued now.
Yep, I also had to rip one to see if using extra force made them come apart, but no luck, it just broke it. However, the one I broke is one that was shorted out and one of the extra 2 that I ordered (phew).

Just be sure to check every single piezo and cross your fingers you don't kill one later on :fingers:
Built:6 t39, t18, 4 Jack10, 2 autotuba, 2 SLA,2 wedge, 2 TT, 2 Tritrix, curved sla, 2 otop212, 2 SLA pros, Ported 8" sub, 2 ported 210, dual ported 8" sub

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LelandCrooks
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Location: Midwest/Kansas/Speaker Nirvana
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Re: Ken's Family Build

#23 Post by LelandCrooks »

On the bright side of that they virtually all seem to work now. I just tested a batch of 250 and had no dead ones. Typically it was always 5 or 6 dead, another half dozen or so with diminished output. They were all good.
If it's too loud, you're even older than me! Like me.
http://www.speakerhardware.com

Ken Lustgarten
Posts: 263
Joined: Mon Jan 04, 2010 9:36 am
Location: Bradley, WV Authorized Builder

Re: Ken's Family Build

#24 Post by Ken Lustgarten »

LelandCrooks wrote:On the bright side of that they virtually all seem to work now. I just tested a batch of 250 and had no dead ones. Typically it was always 5 or 6 dead, another half dozen or so with diminished output. They were all good.
I am going to order another batch of tweeters from you today along with parts for 3 Wedghorns. I want to keep a dozen or so extra piezos of the ones I have that do come apart just in case I end up with a bad one down the road. This will make it easy to replace an element if one ever goes bad. I am going to try using a heat gun and see if I can get one apart intact. It would be good to know that replacement elements are possible.

If quality has taken a large step for the better it is a worthwhile trade off to deal with the glue.

Ken Lustgarten
Posts: 263
Joined: Mon Jan 04, 2010 9:36 am
Location: Bradley, WV Authorized Builder

Re: Ken's Family Build

#25 Post by Ken Lustgarten »

I made some more progress last night. You can see the pictures here

https://picasaweb.google.com/klustgarte ... v-39r_gvQE#

Some of the pics have comments on them. Tonight I want to put the horn braces and sides on the DR250's. A few more evenings of work and I should be able to do a test :hyper: The build process does go a little slow since I am doing 8 simultaneous DR's!

Ken Lustgarten
Posts: 263
Joined: Mon Jan 04, 2010 9:36 am
Location: Bradley, WV Authorized Builder

Re: Ken's Family Build

#26 Post by Ken Lustgarten »

I made some more progress over the weekend. Yard work got in the way but I still manged to get some things done.

The DR250's are in the home stretch. It should only be a few more days until I can give them a test run. Part of me wants to skip the finish and do a test now but I think I can wait another day. Today I will make the crossovers, mount them, round the edges. Well see how much time I have maybe I can start painting them.

I did a little more on the DR200's also. The horn sheaths are all on. I would like to get the braces on tonight. I also ran out of PVC so I need to get some more to finish the last 2 speakers. I am going with variable tuning but I need to get the right size hole saw for the couplers.

Has anyone here used adjustable tophats with a square back 250? I am wondering about the balance point and if placing them in the access cover works good.

https://picasaweb.google.com/klustgarte ... 3qD9xsuBDQ#

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LelandCrooks
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Re: Ken's Family Build

#27 Post by LelandCrooks »

Farther back. Bump right up against the baffle. Mine are partially cut into the baffle.
If it's too loud, you're even older than me! Like me.
http://www.speakerhardware.com

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DanielNY
Posts: 536
Joined: Sun Sep 20, 2009 11:45 am
Location: New York City

Re: Ken's Family Build

#28 Post by DanielNY »

LelandCrooks wrote:Farther back. Bump right up against the baffle. Mine are partially cut into the baffle.
+1

My DR's have metal butts and square backs just like the OP is building and I found the COG to be just forward of the baffle. This means I had to cut into the baffle and the center of the adjustable tophat sits just forward of the baffle. This gives me great balance, no leaning forward or back even at extreme angle adjustments and 7ft high.
Built: T-60's, T48's, T-39's, DR250's, DR200's, Pro SLA's

Ken Lustgarten
Posts: 263
Joined: Mon Jan 04, 2010 9:36 am
Location: Bradley, WV Authorized Builder

Re: Ken's Family Build

#29 Post by Ken Lustgarten »

Thanks for the info on the hat. I ended up routing the covers for a standard hat. The next time I make a set of DR's most likely another pair of 200's for myself I will eliminate the bottom access cover and use the adjustable hats. I am real close on the 250's, pictures later tonight.

Ken Lustgarten
Posts: 263
Joined: Mon Jan 04, 2010 9:36 am
Location: Bradley, WV Authorized Builder

Re: Ken's Family Build

#30 Post by Ken Lustgarten »

The DR250's are operational. They are finished with Duratex. I still have to do some finishing touches such as add more screws to the tweeter arrays and mount the tophat in the lower access cover. I also want to add some more hot glue to the crossover, I wanted to test them before I went nuts with the glue. Here are some pics of the progress that I made in the past 2 days. I tested each speaker individually and stacked. They do sound really nice stacked! I tested them at work and had to keep the volume pretty low, to many stuffy old people at the very conservative Christian College that I work for. I used 4" ports snice the 250's will never be used with subs. They have enough extension for there intended purpose and will work very nicely.

https://picasaweb.google.com/klustgarte ... ZjqwYPmtwE#

Next I will be back on the DR200's. I need to finish 4 for now and then move on to a pair of T39's

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