2 x DR250 (melded) + 2 x DR250 (CD horn) March 2012 plans. Completed

[Bill Fitzmaurice]

A drill press and spade bit would work fine, but it would require that the module be securely clamped to the press table, otherwise all sorts of nasties could ensue.

[Grant Bunter]

A drill press and spade bit would work fine, but it would require that the module be securely clamped to the press table, otherwise all sorts of nasties could ensue.

^ True be that!
I'm not good with spatial awareness when it comes to woodwork, so for me to use a drill press with a spade bit and line it up so it would drill the hole (and not cut into the backing plate) perfectly first time would present a challenge I wouldn't care to take on...

Bill, thanks for challenging me!
I topped woodwork and metalwork in school (which was a long time ago). I am mechanically adept. Your designs, with what I have built so far, keep me on my toes!

The funny thing is, when these DR's are said and done, they will look like ordinary square boxes (well at least from the front).
You can read the plans all you like, but until you've started to build one, you have no idea what goes on inside...

My wife was looking at the cab today, her first comment was "that looks quite spacey and, alien"

[Grant Bunter]

Since there is some interest in the tubes and the method, and some people are visual learners:

Here's the sheath drawn up to cut:
You will note the 1/2" hole for access for the jigsaw blade, and the 3/16" hole drilled from the back of the mounting plate and through sheath which becomes the centre for measuring.
The arch I described earlier is visible and is only a hand drawn guide. Trimming as necessary may be required.

Holes are now cut, with rough cut tubes hot melt glued in place:

3 minutes later, trimming after tubes are hot glued in place and allowed to set:
3 down 2 to go...

All trimmed down after putting on bondo and sanding. What deficits?:

After bondo/bog and sanding, black makes everything disappear (the white you can see in
the pic is set hot melt glue picking up the flash):
You can note the back halves on cab 1 behind...

Critical elements in this process:
Any cut with the jigsaw needs to allow the jigsaw blade to stop fully before any movement, or large deficits in the sheath are likely to occur (learnt on the first attempt).
The openings into the sheath require small adjustments from the hand drawn arch to allow the tube to be centred on the initial hole.
When doing the lower half of the arch, remain aware of the angle of your jigsaw blade. To steep and you start cutting into the backing plate...


I've been in a mad rush to get somewhere further ahead (in my own mind) because we are off to central Queensland come Monday to catch up with my wife's boy who is head stock man (you guys in the States might call him a cowboy ), he runs a property that is just shy of 1,000,000 acres. We haven't seen him for a while and it's a 1000 mile trip.
So my builds will come to a grinding halt...
Tomorrow is my last day, so I'd like to get sides on Cab 1!


I spent another 5 hours today (day 13, includes cleanup time)

[BassMe]

Where in Central Queensland Grant?

Most of my family is based around Rockhampton and Mackay. My parents operate a mobile seafood business through Blackwater and Emerald.

1 milllion acres isn't a bad patch of dirt. Bigger than the biggest ranch in the states

[Grant Bunter]

Where in Central Queensland Grant?

Most of my family is based around Rockhampton and Mackay. My parents operate a mobile seafood business through Blackwater and Emerald.

1 milllion acres isn't a bad patch of dirt. Bigger than the biggest ranch in the states

Hey Bassme
We are off to Longreach!
Not where my wife's boy works, but where we can catch up with him...

And if I remember correctly, the largest property in Australia is well over 1 million sq K's...

[BassMe]

You can keep Longreach all to yourself this time of the year. Bloody frigid place. Might be a balmy for you though coming from NSW.

[Grant Bunter]

You can keep Longreach all to yourself this time of the year. Bloody frigid place. Might be a balmy for you though coming from NSW.

I reckon I'll get a swim in, just to make the locals go

[Bill Fitzmaurice]

for me to use a drill press with a spade bit and line it up so it would drill the hole (and not cut into the backing plate) perfectly first time would present a challenge I wouldn't care to take on..

It's quite simple, using the depth stop on the press.

[Grant Bunter]

for me to use a drill press with a spade bit and line it up so it would drill the hole (and not cut into the backing plate) perfectly first time would present a challenge I wouldn't care to take on..

It's quite simple, using the depth stop on the press.

Of course

I have to say though Bill,
A spade bit would leave quite a deficit in the area that I'm calling the arch. I found that out in the first one I did. It was doing the first one with a drill by hand that made me realise you need to do an arch to not take away to much sheath...

[Grant Bunter]

Today was day 14.
5 hours all up including cleanup.

I wanted one cab pretty much done before going away. Done as in all timber work completed.
I've achieved it
On cab 1, back halves trimmed top and bottom. Flush trimming bit on the router made short work of most of that, hacksaw blade for the remainder, then the sander.
Then both full length sides added.
The back put on with cosmetic options.

No time to take a pic, you'll have to believe me lol.
Seriously, will put the pic up here when I get back.
Of course there is still driver and piezo array to put in, crossovers to be built, dual NL4 plate to put in, painting and corners to put on...
And cab 2 to catch up to the same point. At least now I have other things to do while PL is setting on cab 2.

Now I can answer my own question.
Can I build a DR?
Hell yes!

[LelandCrooks]

Now I can answer my own question.
Can I build a DR?
Hell yes!

[Titanium Hand]

Bloody Oath you can! Industrious Aussie all the way. Have a safe trip up to QLD. looking forward to seeing the finished pics when you get back

[Grant Bunter]

Righto,
Back from central west QLD.

As promised.
One cab completed, with melded array (diffuser yet to be added), 2 sides and back on...

Should I include my finishing time?

I spent 45 minutes on cab 2 today removing screws and filling holes with PL

Spent a few hours trimming/sanding/hole filling cab1 ready for painting...

[Scott Brochu]

Good job.

[Grant Bunter]

Thanks Leland, TH and Scott!

Did a few hours today. Mostly on finishing touches on cab 1
So, rounded edges with 3/8" roundover bit.
Sanded all PL or bondo.
Pics will tell the rest lol...

I should have put the next 2 pics up yesterday. Oh well

Just to prove it has a back:

Cutout is for dual NL4 plate
I like Bill's idea of putting the NL4's in the bottom for pole mounting, but I wanted to ensure the chamber is fully sealed.

This one shows the opening for the adjustable top hat and a good view of the cosmetic option result if doing the full back:

Even though it's snowing here today (which is not common, happens maybe once or twice a year) I decided to put some paint on...

Black just makes everything disappear (done with "Rockard", like Duratex)
Plain small foam roller and small brush for the inside and module. 1 coat.

Fine grade texture roller for the outside:

Then started into the filters.
I need to mull over how to make the piezo filters fit on a small piece of 1/4" ply and leave enough tails on the 4 ohm resistor in case I find the piezos too bright.
The plan is to mount the assembled (by me) filter boards on the bottom of the driver chamber, LF LP on one side and HF on the other, either side of the tophat.

I'll show a shot of the filters when done...