Jack 15

[DaveK]

I'm finally getting around to posting some Jack 15 tricks I came up in my build a few months ago.

1) A way to cut the phase plug disks using a table saw instead of a router. (A bandsaw would be best, but I don't have one.) This is a lot faster than using a router.

2) Hollow out the middle phase plugs to save a few ounces.

3) A template for the baffle is essential to getting a good result. Instead of investing in a full template for a single cab build, I created a temporary one by tacking a phase plug circle and some scrap strips in place with brads.

4) Then rough cut with a jigsaw and finish with a router.

5) The finished baffle and throat assembly.

[DaveK]

6) I've found it easier to install the front and rear stiles before installing the sides. They keep the top and bottom spaced properly, which is important with Arauco that likes to warp.

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7) The horn panel construction method is slightly different to create an inset for a grill made from 1/2"x1/2" stock. A 3/4" stile gives the grill frame a solid backing. The horn panels span the gap between the throat panel and the stile. The horn panels are also 1/4" ply to save weight.

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[DaveK]

8 ) I made a luggage handle using hardware from a folding hand cart. The housing attached to the back panel gives it protection and a good anchor point. Also note the notches in the lower back corner for wheels. Finally, a 4U rack case tops it off. The rack case is attached to the main cab with machine bolts and T-nuts so it is secure, but can be removed easily.

[88h88]

I like the trolley idea. Genius. Looking really nice too, good job.

[DaveK]

The finished result with a bass for scale

[NeilD321]

3) A template for the baffle is essential to getting a good result. Instead of investing in a full template for a single cab build, I created a temporary one by tacking a phase plug circle and some scrap strips in place with brads.

Wish I'd thought of that one.

[Jon Barnhardt]

1) A way to cut the phase plug disks using a table saw instead of a router. (A bandsaw would be best, but I don't have one.) This is a lot faster than using a router.

A properly sized hole saw is even quicker

[doncolga]

Beautiful man...really nice!

[Harley]

The finished result with a bass for scale

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Very Nice!

[DaveK]

A properly sized hole saw is even quicker

Good point. You would need a hole saw with a 5" *inside* diameter and a steady hand to avoid wobble. I don't have either

[Harley]

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So all we need is a shot of your shop, and going by the clean build, you're up for the 5 Harley star ...or have you already got one?

[DaveK]

So all we need is a shot of your shop, and going by the clean build, you're up for the 5 Harley star ...or have you already got one?

My "shop" has been converted back to it's primary job of storing automobiles that get driven every day and boxes of junk that really should be thrown away some day. Oh, and storing the ever growing pile of BFM speakers that don't get used as often as I would like.

[cheapbasslovin]

5) The finished baffle and throat assembly.

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This octagonal outer edge would have saved me much grief with my crappy tools; such a simple thing to overlook . Live and learn.

Nice build.

[Harley]

This octagonal outer edge would have saved me much grief with my crappy tools; such a simple thing to overlook . Live and learn.

I don't even bother with octagonal, I leave the outside square - less cutting time and really, it's bugger all weight saving going round or octagonal considering.