Ken's Family Build
Posted: Mon Apr 25, 2011 2:27 pm
I finally am getting started on a series of builds. 6 X DR200’s, 4 X T39’s (2-BP102 & 2-Lab12), and 2 X DR250. The DR200’s and T39’s are for me and the DR250’s are for the college that I work for. They have a group of 9 students that go on tour performing for the entire summer. As compensation they get a free semester of college. The equipment that they have is complete garbage but that is about to change with a pair of DR250’s. I also just got them 9 Audio Technica 3000 series wireless with Countryman mics and a new Yamaha powered board. I would rather not go with a powered board but the group usually does not have any members that are in the least bit technical so brain dead simple was a requirement. As is, I continually get calls to troubleshoot while they are setting up.
This will be my first BFM build. I thought I was going to have almost 3 weeks to myself as my wife and kids are visiting her family. She wants to come home earlier so that leaves me with only 1 ½ weeks. After that things will move at a slower pace so I need to get as much done as I can now.
I will be starting with the DR’s first and bulk cutting parts. For many operations the setup takes more time than the actual cutting so building several at a time will greatly help to speed up the process, unless I make a mistake X 6.
Day 1
Since I didn’t have wood yet I cut up some piezos. I made a cutting jig that allows me to gang rip 5 at a time. The jig has 2 sides with different spacing to allow both sides of the tweeter to be cut. I am still debating on how I want to cut the 45’s. I am going to try it on the band saw with a jig. The nice thing about the band saw is that there is no vibration so I should be able to hold the tweeters in place safely while I cut.
https://picasaweb.google.com/klustgarte ... v6N4LCzzAE#
Day 2
First up 6 DR200’s
I picked up 15 sheets of Arauco. Since the closest place to get good ply is over an hour away I made sure that I would have plenty for all of my projects (W.V. is a poor state and lumber yards only carry the cheapest materials available). I made the initial crosscuts outside on a cutting table. A guide rail with a square and repeater was used to make exact duplicate cuts. After the ply was broken down I took the parts into the shop for further processing. Cutting compound angles and exact duplicate parts is easy. Set the saw to the desired bevel and use stops (scrap wood) for the angle and length. The Hilti saws make this job very easy. They are designed as a track saw and have precise bevel adjustments and dual locks. Any circular saw will work but the Hilti’s are a pleasure to use.
Day 3
Next was to cut the rectangular holes. I set this up on my bench so that there is no measuring involved, just place the part on the table against the stops, clamp, and rout.
The rings were cut with a Jasper jig and a router. The Jasper jig is the best way I have found to make speaker cutouts. If you have never used one or make cutouts with a jigsaw you should give it a try.
Day 4
Driver filers made and installed, strips were beveled and ripped, then gang crosscut to size. Driver access holes were cut and the tops/bottoms were attached.
Here are the pics of the build as of last night.
https://picasaweb.google.com/klustgarte ... k97hxfycQw#
This will be my first BFM build. I thought I was going to have almost 3 weeks to myself as my wife and kids are visiting her family. She wants to come home earlier so that leaves me with only 1 ½ weeks. After that things will move at a slower pace so I need to get as much done as I can now.
I will be starting with the DR’s first and bulk cutting parts. For many operations the setup takes more time than the actual cutting so building several at a time will greatly help to speed up the process, unless I make a mistake X 6.
Day 1
Since I didn’t have wood yet I cut up some piezos. I made a cutting jig that allows me to gang rip 5 at a time. The jig has 2 sides with different spacing to allow both sides of the tweeter to be cut. I am still debating on how I want to cut the 45’s. I am going to try it on the band saw with a jig. The nice thing about the band saw is that there is no vibration so I should be able to hold the tweeters in place safely while I cut.
https://picasaweb.google.com/klustgarte ... v6N4LCzzAE#
Day 2
First up 6 DR200’s
I picked up 15 sheets of Arauco. Since the closest place to get good ply is over an hour away I made sure that I would have plenty for all of my projects (W.V. is a poor state and lumber yards only carry the cheapest materials available). I made the initial crosscuts outside on a cutting table. A guide rail with a square and repeater was used to make exact duplicate cuts. After the ply was broken down I took the parts into the shop for further processing. Cutting compound angles and exact duplicate parts is easy. Set the saw to the desired bevel and use stops (scrap wood) for the angle and length. The Hilti saws make this job very easy. They are designed as a track saw and have precise bevel adjustments and dual locks. Any circular saw will work but the Hilti’s are a pleasure to use.
Day 3
Next was to cut the rectangular holes. I set this up on my bench so that there is no measuring involved, just place the part on the table against the stops, clamp, and rout.
The rings were cut with a Jasper jig and a router. The Jasper jig is the best way I have found to make speaker cutouts. If you have never used one or make cutouts with a jigsaw you should give it a try.
Day 4
Driver filers made and installed, strips were beveled and ripped, then gang crosscut to size. Driver access holes were cut and the tops/bottoms were attached.
Here are the pics of the build as of last night.
https://picasaweb.google.com/klustgarte ... k97hxfycQw#
