Davids for Tom

[publicIdaho]

I have two boys, one named David and the other is Tom. Tom was the one getting way into music and tired of listening to crappy headphones. Having made my own speakers twenty years ago, I figured we could make him a pair good speakers for Christmas.

The search had us leaning toward the Tritrix kit - great price and the reviews seemed pretty good. But then we came across the BFM site (I have been wanting to build a sub forever and was looking up DIY subwoofers and found the raves for the tuba) and here was the David. It was going to cost more, but the Davids have some balls; more bass and high efficiency. Normally, a dad might not really want to get high efficiency speakers for his teenager, but the speakers are going to mom's house, not mine, so problem solved.

So here we go! Lets build some Davids!!!

Not much time today, but got the major pieces cut out.

Some background: my dad and I have a cabinet shop, so there might be some tool envy out there. Lets start start with the biggie in the shop that makes things easier - sliding table saw.

[publicIdaho]

The basic panels do not make much of a pile - that cart has been on the verge of collapse many times holding the carcass pieces for various kitchens we have done.

[publicIdaho]

These speakers are going to be lacquered gloss black, so I do not want any plywood edges showing. They are a tremendous pain to seal and finish, and probably are not quite as tough/stable as a hardwood edge. I also am planning on rounding the edges over where I can, so I need solid edges.

Found some alder in the bin and cut it it to 5/8" X 5/8". Kept it oversized so I can sand the edgeband flush and then trim the panels to size. Hurrah for sliding table saws! When gluing the thin stuff, make sure to either use lots of clamps or get a wider board that will spread out the pressure.

[publicIdaho]

All the side panels, fronts and backs glued up top and bottom. The fronts and backs will still need both edges banded with solid material.

More to come!

[Tom Smit]

Yup. Tool envy.

[subharmonic]

If you need another son to make Davids for....well we might be able to work something out. I could use gas and money for the movies too!

[publicIdaho]

I can't afford the one that is interested in the speakers - probably because I seem to be adding to my stereo stuff too. Oh, so there is a sale you say on the woofer for the THT??? And the amp that is perfect for the THT is also on sale? Need one of those as well.

As for tool envy, the big one that most people don't clue into until they start doing a bunch of this is the clamps. People come in and see the big saw and other power power tools and say "Oh, I wish I had that," but having enough clamps, that is the stuff. We finally have enough for summer - by the time we use up all the bar clamps gluing up doors when it is hot, we can take the first clamps off and keep on going. Had to do that this summer - we did a huge kitchen that had ~60 doors.

Pony clamps are more expensive than others, but they are definitely superior. We always use our Pony clamps before the others.

Tip: if you do make yourself pipe clamps, use galvanized pipe; black pipe will stain your wood if you get wood glue that is on both black pipe and the wood.

Tip 2: if you have threads on the end of your pipe (and can keep from banging them up too bad) you can use a pipe coupling and another piece of pipe and all of the sudden your 4' clamp can be 8', 12' - what ever you need.

[subharmonic]

As for tool envy, the big one that most people don't clue into until they start doing a bunch of this is the clamps. People come in and see the big saw and other power power tools and say "Oh, I wish I had that," but having enough clamps, that is the stuff. We finally have enough for summer -

-1 There is no such thing as enough clamps. BTW Ace hardware has 16" bar clamps for $5 each in my neck of the woods.

+2 on the rigid pipe tips

[Michael Ewald Hansen]

Gonna follow this one closely.. Not often people build davids and not at all with this amount of tools - envy!

[Scott Brochu]

Love that table saw

[Traijin]

Gonna follow this one closely.. Not often people build davids and not at all with this amount of tools - envy!

Exactly, thank for taking the time to post good pictures... I just picked up plans for the Davids yesterday. This was going to be my winter project. I will also be watching how you finish them, I did a piano black two part catalyzed finish on my SLA's shot with a turbine HVLP. Curious how you'll do yours.

[Alien]

Tip 2: if you have threads on the end of your pipe (and can keep from banging them up too bad) you can use a pipe coupling and another piece of pipe and all of the sudden your 4' clamp can be 8', 12' - what ever you need.

That's one I'd never thought of. Thanks

A

[publicIdaho]

Too nice outside today, first sunny day in over a week - had to go golfing instead of building speakers.

As for the finish, we run a pressure pot with an HVLP gun. We have recently started using catalyzed lacquer - it is much more durable than the regular lacquer we have been using for years. It also does not dissolve into the previous coats, once it is dry, it does not come off when rubbed with lacquer thinner. We are liking it, but once catalyzed, it has a shelf life of a few months.

I am planning to go into the details of the finish when I get there - I figure I will have way more time on the finish than the build.

[LelandCrooks]

Ah man you have the sliding table I want. I have one, but it's a smaller capacity.

Yup, never too many clamps. I've gone to these: http://www.adjustableclamp.com/90degree ... lamps.aspx
mostly because I bought a pile of them at 1/2 price of wholesale on a closeout.

[publicIdaho]

I picked up some Chinese Pony bar clamp copies from Harbor Freight when I lived in Southern CA and had those stores around - they are are not as good as the Pony clamps, but they were ~ $6 a set. So we now have this.