BillFitzmaurice.info

Will you be putting grills on the cabs? If so, you can put a piece of air conditioner filter behind the grill and no one will ever see any blemishes on anything. Aside from spray painting the mouths of my OTops flat black, I didn't do anything to the arrays...and they have lots of PVC glue spots/blemishes on them. See my build thread for some pics; the mouths aren't too pretty but what do you see afterwards? Nothing.

Now, if you won't be putting grills on them at all, I hope that you have protected the Delta's somehow...pet screen or other screen-type fabric (can't remember if you've done that already).

MisterB wrote:Array from the back with wires in place (they're all soldered in now)

You are making good progress with you arrays

If you want to spray the arrays, you may want to remove the driver elements beforehand, so you do not get paint on the cones. Just the three screws on the rear side to take them apart. Upon reassembly, you can then also rotate them by 120 degrees, making it easier to wire series/parallel. At least for my brain it was easier.



If you look carefully, you will see that I also made alternating cuts in my pizzers, so the screws don't get in the way of their neighbours. Not much use on arrays that have already been glued and wired, but just a thought to keep in mind if you still have one more to go.

I managed to do the preliminary cuts for all my panels for one top, mostly just rectangles and squares without the miters and compound angles yet..... and then my wife got me a beer brewing set-up for Christmas... as if I need another hobby! I got a little distracted from my build by brewing my first batch. Now it's just fermenting and I also got myself a router for Christmas, so I finally got back to it last night. I keep reminding myself I don't actually have a deadline for this project. Shoot, I've already been working on it since last year

I decided to use my new toy to do the cutouts in the baffle. I clamped a guide board in place to get straight lines with my router cuts then used another new toy, the Jasper Circle jig, to cut the circular parts. It took a good long while to do it, moving the guide board for the different sets of cuts and setting up the circle jig, but I'm pretty happy with the results.

Nice baffle! I commend your patience in cutting the whole thing out w/a router. Hopefully, you're aware of pattern bits? You can use that pretty baffle that took 5 hours to cut out as a template and bang out the other one (or however many) in about 5 minutes each.

miked wrote:Nice baffle! I commend your patience in cutting the whole thing out w/a router. Hopefully, you're aware of pattern bits? You can use that pretty baffle that took 5 hours to cut out as a template and bang out the other one (or however many) in about 5 minutes each.

+1

miked wrote:Nice baffle! I commend your patience in cutting the whole thing out w/a router. Hopefully, you're aware of pattern bits? You can use that pretty baffle that took 5 hours to cut out as a template and bang out the other one (or however many) in about 5 minutes each.

I was not yet aware of them. I'm honestly such a noob with a router that I was racking my brain trying to figure out how the heck people use templates. I saw that the cutting edges of my bit go all the way up to the collet so I couldn't conceive of a way that a template could be used without routing the template itself. I was just figuring I'd take several more hours to knock out the other one of the pair when I'm ready. A quick google search of pattern bits and I see how it works.

Thanks!

A little more progress.



Tweeter arrays are painted... pretty easy to notice on left array that I trimmed bottom and top off 2 piezos too many. I figure I can still find a way to mount it. Should still function as intended and the error won't be so visible behind a grill or against the rest of the cabinet that's painted black.



Woofer spacer and phase plugs cut. I sure do love my Jasper circle jig And my wife's miter saw sure came in handy for cutting the corners on that woofer spacer. When I can use her saw for those kinds of cuts, I'd much rather use it than trying to miter on the table saw.



Dry fit of baffle, spacer, and phase plugs. Everything lines up nicely and looks good!

MisterB wrote:And my wife's miter saw

You must be a very happy man (or is it that YOU bought her the saw for 'her' Christmas present)

escapemcp wrote:

MisterB wrote:And my wife's miter saw

You must be a very happy man (or is it that YOU bought her the saw for 'her' Christmas present)

Don't laugh......my wife says one of the best presents she ever got was a bucket full of tools for all of the stuff she used to do. Not only was she happy with getting her own tools - so was I!

I'd come home and find her and 5 friends in the garage building floats for parades or sets for plays.......with my tools everywhere.

And that's why she has her own now.

I definitely helped with purchasing the saw. She's an artist and makes her own frames. Until we got the power saw, I often had to help by putting some elbow grease into the old handsaw and miter box method to do the corner cuts for her wooden frames. The power miter saw sure does cut down on my "honey do" list... and it's helpful for certain cuts that I need to make from time to time

Bruce, it's funny you mention the thing about tools being all over the place. My brother and I used to do that with my dad's tools and he'd get so frustrated and we'd snicker about it. Sometimes my wife decides to 'organize' my tools and I can't find anything and she thinks it's funny that I don't get her organization method... as an adult with my own tools I finally understand my dad's pain, may he rest in peace. I'm sure he's in Heaven having a hearty chuckle about it all

A little more progress



I was going to buy some screen then my wife reminded me we have this old screen door that we're not using. I cut out a section and cleaned it up. Yup, that's a halfpipe to the left in the background. I've been building those since the late 80s.



Woofer spacer attached, PL put in screw holes so woofer gasket will have a good seal - I scraped off the excess PL after it dried



Mounting hardware tested for fit and hurricane nuts epoxied in place. Several people recommended using hurricane nuts with screws rather than recex screws due to weight of Delta Pro. Made sense to me



baffle attached to bottom, two horn panels attached. I just bought a light duty brad gun and compressor - it makes things so much easier!!



phase plug extension attached

Slowly slowly catchy monkey. Like you said, no hurry. On the flipside I bet you can't wait to hear them.

Also halfpipes? Do you still skate?

88h88 wrote:Also halfpipes? Do you still skate?

Yes, I still skate pretty often. I'm going to widen the halfpipe one of these days and possibly add a spine and / or hip. I also need to put a new layer of top ply on it. Rain has been killing it. I might also try to change the transition to a longer radius. It's 6' right now and that's quick and a bit tight for my over 40 beer loving self... gotta scrunch that gut pretty good to pump that transition

Getting closer to the completion of the first one.



Top added



Compound angles on throat reflector. After cutting the long edges at 45 degrees, I used a miter saw to do the other cuts. It took some trial and error but came out pretty good... and yup, I did make it 12" wide at the long end rather than the spec - but figured some PL and caulk would close the gap



Throat reflectors installed



Saw sled setup for trimming horn panels flush



nice clean cut



employing the trusty router for handle holes / ports. I used my Jasper circle jig to cut the round parts of the holes. Have I mentioned that I love the Jasper circle jig? I love the Jasper jig.



sides attached - and it'll be a long time before I'm in the running for a Harley award!



did lots of sanding then ran drilled hole for tweeter array wire and ran it through, sealed it up with PL and caulked screw holes and seams.

Getting closer... and I've cut out pieces for second Otop

MisterB wrote:

The problem with this type of screen placed at this stage of build is when you come to spray paint the assembly, some of the little square openings become blocked. You have to then blow compressed air ( carefully ) at the screen and make sure your wife or car is not positioned directly behind