BillFitzmaurice.info

Bruce Weldy wrote:Keep your fingers away from the blade?

I hear you. Been woodworking a long time and never cut myself on the table saw or router table cause they scare me and I'm extra careful. Have nicked myself on the bandsaw a couple times being careless.

jdmrivera wrote:

Bruce Weldy wrote:Keep your fingers away from the blade?

I hear you. Been woodworking a long time and never cut myself on the table saw or router table cause they scare me and I'm extra careful. Have nicked myself on the bandsaw a couple times being careless.

I built myself a really good push stick a few years back.....well worth the time and effort.

Well I didn't work on the mid horn tonight - I'll buy one of those fancy digital angle gauges to use on my table saw tomorrow before I tackle the horn. Instead, I decided to cut 2" and 1" strips and glue them up for the back flanges.

Good thing I have a bunch of spring clamps from my flute making hobby: I also attached the outside baffle brace.

While working, I discovered part of one of my glue joints failed. In this picture, the smeared glue is where I tried to squeeze glue into the joint. I'll probably just use screws to hold this joint and seal it well from the inside unless somebody has better advice. Unfortunately I'm working too many hours at the day job that pays the bills so I have precious time in the evenings. Last two nights as soon as I got home the overalls went on and I headed to the garage. My wife thinks I'm loco especially when she checks the bank account . Looking forward to the weekend.

jdmrivera wrote: While working, I discovered part of one of my glue joints failed. In this picture, the smeared glue is where I tried to squeeze glue into the joint. I'll probably just use screws to hold this joint and seal it well from the inside unless somebody has better advice.

Are you using PL Premium??? That stuff shouldn't fail. You can use screws for clamping power, and once the PL has cured, you can remove the screws.

Tom Smit wrote: Are you using PL Premium??? That stuff shouldn't fail. You can use screws for clamping power, and once the PL has cured, you can remove the screws.

Yes - I'm using PL premium (same stuff called for in plans). Only thing I can think of is maybe joint was not clean or maybe I applied to much clamp pressure and squeezed out too much glue.

Temperature and humidity are critical with PL. At least 60 degrees, and in dry climates spritz the joints with water.

Bill Fitzmaurice wrote:Temperature and humidity are critical with PL. At least 60 degrees, and in dry climates spritz the joints with water.

Could be the problem. Temp was around 50-55 when I was working over the weekend. Always dry here in Colorado. Hopefully I don't have other failures .

Small amount of progress last two nights.

Small back and top installed. Built a small cross cut sled to help with horn parts. Trimmed up back flange pieces. With any luck I can get the horn built tomorrow. Hopefully sneak out of work early

Didn't make it out of work as early as I hoped but did buy a cheap harbor freight brad nailer on the way home and all I can say is "where have you been all my life?" If you don't have one, get one! It was perfect for holding parts while cutting all the horn pieces - I made enough parts to build two horns anticipating I'll build another one of these cabs later.

I got excited and rushed ahead of the plans and installed the back flanges, holding everything in place with 1 1/4" brads. Verified the 15" woofer will fit through the flanges.
Tomorrow I'll install the horn and tweeter and internal bracing. Was gonna work later tonight but the bottle of bourbon in the house was calling my name

More pictures tomorrow.

jdmrivera wrote:Started on my Tallboy this weekend.

For anybody else near Denver Colorado, I found Baltic Birch at Consolidated hardwoods for a decent price. 1/2 inch 5x5 was $45 a sheet.

Here's the basic cab shell:

20170312_124140.jpg

Baffle cut was made with a jigsaw (very slowly):

20170312_155736.jpg

Baffle installed:

20170312_185103.jpg

Everything is screwed and glued which helps assembly proceed without waiting for glue to dry. I'll most likely pull the screws when finished and fill with bondo before sanding everything.

When sitting on it's base there is a very minor wobble (bottom is not totally flat) I haven't decided if I should try to force it out using bar clamps or just make up for it when I install the feet. It's only about 1/8" off but it bugs me.

Is there an update? My OT15TB plans called for a square opening in the baffle...

jdmrivera wrote:Started on my Tallboy this weekend.

For anybody else near Denver Colorado, I found Baltic Birch at Consolidated hardwoods for a decent price. 1/2 inch 5x5 was $45 a sheet.

Here's the basic cab shell:

20170312_124140.jpg

Baffle cut was made with a jigsaw (very slowly):

20170312_155736.jpg

Baffle installed:

20170312_185103.jpg

Everything is screwed and glued which helps assembly proceed without waiting for glue to dry. I'll most likely pull the screws when finished and fill with bondo before sanding everything.

When sitting on it's base there is a very minor wobble (bottom is not totally flat) I haven't decided if I should try to force it out using bar clamps or just make up for it when I install the feet. It's only about 1/8" off but it bugs me.

Not bursting anyone's bubble on cost of BB here, I found a wholesaler in Lou "DSI" cost for 5X5 1/2" sheet is $16.55 no min order.

detroitrockphily wrote: Not bursting anyone's bubble on cost of BB here, I found a wholesaler in Lou "DSI" cost for 5X5 1/2" sheet is $16.55 no min order.

Oh, wow...Just a couple weeks back I drove 10+ miles past that to buy 12 sheets of Arauco @ Menards... Sheesh.

detroitrockphily wrote: Is there an update? My OT15TB plans called for a square opening in the baffle...

There is a square opening for the baffle on the midrange driver. It's round for the large woofer.

Measure twice cut once!!
Good new is I cut out two sets of midrange horn pieces and successfully built one of them. Bad news is I then proceeded to trim it to 10" long instead of 11"
Need a few minutes to de-compress then go build the other one.

Take two:

Second horn glued up. Will trim tomorrow........... I drew lines on both sides of the top and bottom pieces to use as a guides when shooting the brads.