Building Trio of Wedgehorn 10s

[Bruce Weldy]

Decided to wire up the arrays today while I decide whether to use a single 2x jack plate or put singles on each end. Tried cutting some aluminum to make single plates.....that was an abject failure and a waste of time. Don't like the plywood option - not sure that there is room for the screws to grab in the wood without tearing out.

[Bruce Weldy]

How can you not love soldering all afternoon?

[Bruce Weldy]

Got the array supports in and added mounts for the grills...just not enough of the horn to screw into on the top and bottom...

[Bruce Weldy]

Seems as though I'm doing everything I can do to put off actually sticking the horns in the shells. But as of now, there's nothing left to do.....routed out for the jack plates this morning.

[Bruce Weldy]

Moment of truth....putting the horns in the shells. This is probably easier if you aren't putting on grills. With grills you need to recess the horn about a half an inch. So, I tacked two strips of 1/2" ply across the horn.

Then turned it upside down, buttered it up with PL and slid the shell over the top.

Voila......3 Wedgehorn 10s ready for bondo, sanding, paint, duratex, and speakers.

[Bruce Weldy]

They are all ready for paint, but decided to add some impressions on the ends for stacking. First built a template on the other end of my jack plate template - then routed 'em out.

Headed out to start painting.

[Mike Taylor]

Bruce I'm completely impressed!

[Bruce Weldy]

Thanks Mike.

First coat of duratex is on. Have I ever mentioned, that stuff is amazing? Yeah, I know, a hundred times. I'm almost finished with my first gallon after double-coating 2-T39s, 2-OT12s, 2-light boxes, and 4 coats on another 2-OT12s.

And most importantly, I opened this gallon a year ago. And it is still just fine.

I'll probably have to bust open the new gallon. When I'm done, I'll have 95% of that gallon left.....with no more projects on the board, I may paint the fascia boards.

[Bruce Weldy]

After a two-week hiatus, I finally got back to work on the Wedgehorns.

Finished up the dampening with mattress topper. Originally, I had used a spray glue to put it in, but it didn't hold. Went back with a stapler - there is very little room in there to get a stapler in.

There is also very little room for the back screws on the speaker. Be sure and pre-drill them angled out and to the front. Otherwise it's impossible to get in there to tighten 'em. And as Bill pointed out, it requires a ratchet with u-joint on a long extension to get back there.

The melded array is wired to the crossover using an electrical connector (spade type). Found 'em in a package with blue and red - one for positive, one for negative. Besides the color, they are a different size - so they can only go back together the right way.

[Bruce Weldy]

Next up was the Jack Plate......since I occasionally see questions about wiring the parallel NL4s, here's the way I do it. Just make a short pig-tail. Twist it to the main wire and solder them together. Tin the other end and the connectors on the NL4s.

Here's the inside with all components installed.

[Bruce Weldy]

Well, it was time to fire 'em up to see if everything was right.....

No problems. All three were born alive and kickin'. You can see the old Peavey head in the background powering 'em. Had all three of 'em blasting away in the garage - never got more than 175 watts for all three of 'em.

Surprised by the low end, but that's in the garage. I'll be A-Bing them with my Yamahas that I've been using this week. I'll do a separate review then.

Today started working on the grills and foam backers. Couldn't find foam large enough - had to splice with masking tape and cut to size (the blue painter's tape won't stick to the foam btw..)

Sprayed the back of the grill and put the foam on top, put a plywood panel on top and weighted it down. Curing now.

[Bruce Weldy]

Checked after a couple of hours......didn't stick. Re-sprayed, weighted down, and left overnight. Much better.

So, then I cut foam for the rest of the WH10s and the 4 OT12s. Buttered up all the grills, put on the foam, covered them all with a large piece of BB and stacked two WedgeHorns and an OT 12 on top to keep the pressure on. Left 'em to cook overnight. Worked just fine. Installed the grills this morning.

Next up was the corners....

Did some cogitating on how to make those square plastice corners fit on the non-square wooden corners......came up with three different designs that worked really well. The plans show just cutting off the ends, but that doesn't allow for coverage of the corners where they are going to get dinged. These cuts allow for them to be positioned on the corners and still lay flat.

Here's what they look like installed....

[Bruce Weldy]

That brings us to the conclusion of the WH10 Build. Mr. Webber kinda' set the bar really high on building this box, but I think these turned out pretty good. I hope to have a review later in the week after I compare them to the Yamahas we've been using and put 'em to the test this Saturday night.

bidee,bidee,bidee, That's all folks!

[Dantreige]

Very nice work! Can't wait for the review and comparision to the Yammies.

[Bruce Weldy]

If anyone is interested, these 3 WH10s may be up for sale soon.

Haven't set a price or listed in the For Sale section yet, but thought I'd put it out there to see if anyone is interested. Will probably be willing to sell loaded or unloaded. Might use the drivers for some Jack 10s.