Curved Grill WH10

[N.Webber]

The past two weeks or so were slow re. the WH10 as I was busy with gigs.
… Such as this one on last Saturday (DR290s over LABhorns):



So, last week I got the Padded covers. The man took the liberty to change my design a little
but they turned out really nice and fit perfectly, easy to dress onto the wedges and wide Velcro closing on all edges:



Another view:



Yesterday and today I spent some time building a jig for cutting the piezos.
The Jig in open/empty position:



The 1016 piezo located inside the jig:



And here closed, clamped and ready for cutting:



This setup is for the array end piezos that are cut only on one side.
The rest will be trimmed on the other side also by rotating them and a spacer inserted into the jig.

Hopefully tomorrow…

[N.Webber]

Piezos are cut:



I'll be using Bill's black ABS glue…
Some of the scraps were chopped into a jar and topped with MEK.
We'll see how it works.

[N.Webber]

BFM's DIY ABS glue ready:



Tested on scraps of the Piezos...



This stuff is the real thing! Applied only a thin bead on the mating surfaces,
left to set for a few hours and the bond is as strong as the original material.

Here is the result of trying to break the bond with pliers…



Next: gluing the arrays

[bzb]

Your jig looks nicer than my builds.

Knowing how meticulous you are, how do you plan on touching up the arrays? I'm thinking of grabbing some of those circle labels at Office Max to cover up the center hole.

[Bruce Weldy]

Your jig looks nicer than my builds.

Knowing how meticulous you are, how do you plan on touching up the arrays? I'm thinking of grabbing some of those circle labels at Office Max to cover up the center hole.

If you use grills and foam behind them, you don't have to touchup.....they can be as ugly as your mother-in-law and nobody knows!

[N.Webber]

If you use grills and foam behind them, you don't have to touchup...

+1

But if you must, I think a circular sticker will be difficult to place because of the throat plug shape, unless you pick a bigger diameter and make a cone of it…
I am planning on using foam/sponge plugs just tucked into the throats while cutting the 45 deg. to keep the business area clean.
The same can be done for touchup. Or, you may find (or make) paper/cardboard cylinders of the right diameter that fit snugly in there.

[matthewmdn]

The DIY ABS glue is cool, but is there any reason not to just use the ABS glue I already have? Is it just a better match or is there something chemically different?

[Bill Fitzmaurice]

The DIY ABS glue is cool, but is there any reason not to just use the ABS glue I already have? Is it just a better match or is there something chemically different?

DIY is thicker and the color matches. You can drop shavings into a standard multipurpose clear glue to tint and thicken it too. Give them overnight to dissolve. If it gets too thick add some thinner/cleaner.

[N.Webber]

The DIY ABS glue is cool, but is there any reason not to just use the ABS glue I already have? Is it just a better match or is there something chemically different?

The main reason was I couldn't find (locally) reasonably priced ABS glue in bigger quantity.
The only other option was model glue at hobby shops, that come in small and fancy packages and is pricy.

Also, with the DIY glue, you can control and optimize its viscosity to your liking and the application by adding scrap pieces or MEK.
And finally, it chemically matches perfectly to the materials to be glued, ...and is black.

[bzb]

Your jig looks nicer than my builds.

Knowing how meticulous you are, how do you plan on touching up the arrays? I'm thinking of grabbing some of those circle labels at Office Max to cover up the center hole.

If you use grills and foam behind them, you don't have to touchup.....they can be as ugly as your mother-in-law and nobody knows!

But my mother-in-law is pretty hot for a 55 year old. I was told that was the best way to figure out how hot your potential wife will be

I'm just jealous of all these dudes on here with cool looking blue/red/hot pink arrays.

[Dave Non-Zero]

Your jig looks nicer than my builds.

+1

[N.Webber]

The Piezo quartets are ready:



Next: chopping at 45 deg.

------------

I made this jig for gluing the backing foam to the pre-curved grills.

Here are the parts before assembly: base, ribs and bendy-ply for the curved top.



Jig ready:



Checked to match the grille’s curvature:



The grill foam is placed on the jig:



The grill back is sprayed generously with slow drying black car underbody spray.
The grill is then immediately placed on top of the foam, with light and even pressure
applied to insure full contact with the foam throughout the contact area.
Left to dry overnight (pictured are both grills drying together):



This morning – the foam backed grills are ready:

[Dave Non-Zero]

only you would get the curves precurved. the rest of us would just screw em down.

[N.Webber]

only you would get the curves precurved. the rest of us would just screw em down.

Unless one uses really thin material for the grill, the screws holding the curve down would then need to supply a considerably higher fastening force.
This would probably also make attaching and removing the grill from the cab somewhat tricky.

[Dave Non-Zero]

yeah but the point is - you thought about that before doing it.