BillFitzmaurice.info

Started on my Four Wedge Horn 10's. Baltic Birch, the good stuff, 11 ply. Bought out of Portland, Ore, just south of here, for $32.00 a sheet, very nice stuff. If you have to make a choice, for sure use BB, its so nice to work with. I am using the Deltalite II 2510 driver.

I found it easier for me, to start with PL'ing the 2 sides, the back, the top and bottom. I used a flat top bench, and stood the parts on end, the mouth down, then using #18 brads, and clamps, made sure everything was square, then I added the 4 braces last.

Set over night, and viola!


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...and then there were four.
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More to come...

Lastcat

Looking great man!

If you haven't already, make your self a horn jig. Using the one in the plan to get the Angles right build a sort of pyramid to lay the horn parts on for assembly. Properly place stops to hold the boards in place and you're good. Took me 20 min to put my two horns together. I have two more to go.

Cheers

Benj

Lookin nice!

Thanks Benj, think I have an idea for a jig. See what I come up with.

Handles, make a few 4 sided small boxes, then glue them to the inside. Before I added the boxes, I went with 1" wide handles, and added a 1/2" quarter round molding, to the inside corner. Then glued the boxes over the molding. Then cut a (3/4" Forstner) hole, 1/2" Pattern Router Bit the openings.

I just used a "stick" to hold both boxes in place, while the PL dried. Then used a 1/4" radius bit to the outside of the handle opening.


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Great idea about the handle boxes, very nice.
(you may want to paint the inside of the boxes black on your next batch before glueing them into place)

AntonZ wrote:Great idea about the handle boxes, very nice.
(you may want to paint the inside of the boxes black on your next batch before glueing them into place)

Yep, shoulda done it, hindsight. Oh well, nothing a small foam brush can't do later on.

Thanks
Lastcat

AntonZ wrote:
(you may want to paint the inside of the boxes black on your next batch before glueing them into place)

You kiddin'?

Those boxes look so good that you oughta' put three coats of poly on 'em and show 'em off!

wow!

great build, puts me to shame

Bruce Weldy wrote:

AntonZ wrote:
(you may want to paint the inside of the boxes black on your next batch before glueing them into place)

You kiddin'?

Those boxes look so good that you oughta' put three coats of poly on 'em and show 'em off!

loudsubz wrote:wow!

great build, puts me to shame

+1

Good stuff, keep the pics coming. Don't see a lot of W10 build threads on here.

Thanks jswingchun, will do.

Just finished the Horns, pics soon.

LC

Started the Horns. Cut all the parts for four horns, and four of the Horn Jigs. I scribed a center line on the sides, where the Jig will be applied. I used Permacel Double Stick Tape, the real stuff, not carpet tape. Very handy for holding router fixtures, dry fitting, etc...

I dry fit all 4 pieces, then boxed the outside edges with some scrap 1/2", that I laid on a sheet of plywood. Squared the strips and measured to make sure everything was consistent. Then I added a strip of Permacel to the center line, then applied the Horn Jig, and pressed the 2 sides together. The plywood jig I made was to keep everything up and centered. Made it easy to be consistent getting everything square, for applying PL and using my Brad Nailer.


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Here is the holding strength of the Permacel, very strong stuff.


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I have the top attached, and now just adding the bottom.


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And here we go....here they are drying, I kept the Horn Jig in place.


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Ok, Horn Jig removed, just snapped these pics.


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4 Horns, now on to trimming the mouth, gonna take some time, reread the plans, and see if I can get my small 10" table saw to trim the horns to fit the cabinet, gonna take some thinking here...hmmm.

Lastcat

Lastcat wrote: see if I can get my small 10" table saw to trim the horns to fit the cabinet

The size of the saw isn't a limiting factor, the size of your panel cutting jig is.