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Building the Cabinets
Uploaded Nov 18, 2009 03:18:41
This is the the start of the speakers I build for my home theater setup.
Building the Cabinets 2
Uploaded Nov 18, 2009 03:18:43
Uploaded Nov 18, 2009 03:18:48
The parts arrived! Now to get started.
Speaker parts 2
Uploaded Nov 18, 2009 03:18:50
Speaker parts 3
Uploaded Nov 18, 2009 03:18:52
Uploaded Nov 18, 2009 03:18:54
Cabinets are almost finished!
Uploaded Nov 18, 2009 03:18:57
Working on the crossovers with a friend.
The crossovers 2
Uploaded Nov 18, 2009 03:19:01
The crossovers 3
Uploaded Nov 18, 2009 03:19:04
Putting everything together
Uploaded Nov 18, 2009 03:19:09
Getting the crossovers installed and testing out the speakers.
Putting everything together 2
Uploaded Nov 18, 2009 03:37:00
Putting everything together 3
Uploaded Nov 18, 2009 03:37:13
Testing the assembled speakers!
Uploaded Nov 18, 2009 03:37:15
They sound awesome! I was blown away by how clear the sound is. The work isn't done yet!
Testing the assembled speakers! 2
Uploaded Nov 18, 2009 03:37:17
Starting to stain the front baffle
Uploaded Nov 18, 2009 03:37:23
Sanded the fronts down. I spent weeks testing different color combination on the stain to come up with something vibrant and cool. I was blown away by the results, they look awesome!
Starting to stain the front baffle 2
Uploaded Nov 18, 2009 03:37:35
Starting to stain the front baffle 3
Uploaded Nov 18, 2009 03:37:45
Starting to stain the front baffle 4
Uploaded Nov 18, 2009 03:37:51
The result of the stain!
Uploaded Nov 18, 2009 03:37:57
Applying the last layers of clear coat, the fronts are almost finished!
Front of the speakers is finished!
Uploaded Nov 18, 2009 03:38:04
The fronts are finished, but now I have to build the stands and paint the sides of the speakers. I plan to paint them with a black mirror finish, but it'll have to wait because I'm starting work on a new project for my home theater, the sound room!
Uploaded Nov 18, 2009 03:46:36
The first portion of the framing going up. The walls are recessed from the cement to help avoid transmission of sound.
2x4 framing 2
Uploaded Nov 18, 2009 03:46:43
2x4 framing 3
Uploaded Nov 18, 2009 03:46:44
Electrical and water
Uploaded Nov 18, 2009 03:46:46
Rerouting the main water pipe for the house which previously went across the ceiling.
Uploaded Nov 18, 2009 03:46:50
Wiring the electrical for the lights and outlets. New breaker dedicated for this room.
Uploaded Nov 18, 2009 03:46:54
Pulled out old carpeting and installed the insulation and outlets.
Uploaded Nov 18, 2009 03:46:59
Uploaded Nov 18, 2009 03:47:07
First layer of drywall going up! You can see the acoustical caulking at the base of the 2x4 frames.
Uploaded Nov 18, 2009 03:47:11
Uploaded Nov 18, 2009 03:52:59
Uploaded Nov 18, 2009 03:53:06
Caulking all of the gaps with the SilenSeal Caulking.
Uploaded Nov 18, 2009 03:53:12
Uploaded Nov 18, 2009 03:53:15
Uploaded Nov 18, 2009 03:53:16
70 tubes of Green Glue Noiseproofing Compound to use between the first and second layer of drywall.
Green Glue 2
Uploaded Nov 18, 2009 03:53:18
Green Glue 3
Uploaded Nov 18, 2009 03:53:19
Uploaded Nov 18, 2009 03:53:21
Preparing for the second layer of drywall. The layers will be installed so that there are as few overlapping seams as possible.
Second layer 3
Uploaded Nov 18, 2009 03:58:22
Second layer 4
Uploaded Nov 18, 2009 03:58:23
This is what it looks like before the screws go in.
Tape and mud
Uploaded Nov 18, 2009 03:58:25
Second layer is finished, first layer of tape and mud on the walls.
Tape and mud 3
Uploaded Nov 18, 2009 03:58:32
Uploaded Nov 18, 2009 03:58:34
Mudding and standing is finished, floors are cleaned and a 3rd layer of acoustical caulking along the floors.
Drywall finished 3
Uploaded Nov 18, 2009 03:58:36
Uploaded Nov 18, 2009 03:58:38
First layer of primer on the fresh drywall. The wall primer was tinted so it would be darker.
Uploaded Nov 18, 2009 04:03:31
Painting finished 2
Uploaded Nov 18, 2009 04:03:37
Painting finished 3
Uploaded Nov 18, 2009 04:03:38
Uploaded Nov 18, 2009 04:03:39
<3 Monoprice.com, if you don't know about it you are missing out.
Uploaded Nov 18, 2009 04:03:46
Uploaded Nov 18, 2009 04:03:52
Uploaded Nov 18, 2009 04:03:57
Walls are finished, now it's time to carpet!
Walls done! 2
Uploaded Nov 18, 2009 04:03:59
Uploaded Nov 18, 2009 04:22:22
The carpet is installed! A special thick padding was used to help reduce reflections.
Carpet Finished! 2
Uploaded Nov 18, 2009 04:22:23
Uploaded Nov 18, 2009 04:22:24
Starting to bring stuff in and hook everything up.
Uploaded Nov 18, 2009 04:22:25
Onkyo Surrounds, which will be replaced very soon.
Uploaded Nov 18, 2009 04:22:27
Pioneer PDP-6020FD, Onkyo Receiver the is getting replaced soon, hand built front speakers (which are still unfinished but I'll be getting back to work on them soon).
Uploaded Nov 18, 2009 04:22:35
Rythmik Audio 15" servo subwoofer, if you don't have one, get one. Awesome sub, hands down one of the best I've listened to.
Center channel mount
Uploaded Nov 18, 2009 04:22:36
Finding something that could support a speaker that large and heavy was not an easy task.
Uploaded Nov 18, 2009 04:26:52
Things left to do:
1: Install the door for the room
2: Build sound damping panels and install them.
3: Install baseboards.
4: Build window cover with dampening material and green glue.
5: Build speaker stands
6: Paint speakers (piano black finish) and stands.
1: Second f15 Sub (First is loud enough, but trying to perfect the room acoustics)
2: New surround sound speakers
3: New receiver.
Uploaded Nov 30, 2009 19:54:04
My make shift painting booth and test piece of freshly sanded MDF
First primer layer on test piece
Uploaded Nov 30, 2009 19:54:05
The primer is still damp!
Second layer of primer
Uploaded Nov 30, 2009 19:54:06
The surface turned out very well. We can't test out the paint layers till we prime all the speakers, that'll be tomorrow. I'm using a very high gloss very hard varnish on the speakers, can't wait to see the results.
Starting primer on the speakers
Uploaded Nov 30, 2009 19:54:07
First layer going up on the center channel.
Uploaded Dec 02, 2009 11:28:02
Start of the standing.
Uploaded Dec 02, 2009 11:28:04
Most of yesterday spent standing, first layers of paint should go on tonight.
Last coat is finished!
Uploaded Dec 04, 2009 21:32:02
2 coats of primer, sanded with 400p. 2 Coats of paint, sanded with 600p. Final coat of paint. I have to wait 2 months for the paint to setup before I can start work on the mirror finish.
Turned out beautiful
Uploaded Dec 04, 2009 21:32:09
Can't wait to get them back in the theater room!
Uploaded Dec 04, 2009 21:32:11
I should of cleaned off the lint from pulling down the painting booth I setup before taking the picture, but otherwise a perfect finish.
Finally get to take off the tape!
Uploaded Dec 04, 2009 21:32:17
How sexy is that. Sorry the picture is a little dark, I had to borrow my friends camera for this one because my camera doesn't want to work.
Uploaded Dec 04, 2009 21:32:24
The black really brings out the red in the finish.
Uploaded Dec 04, 2009 21:32:28
Uploaded Dec 04, 2009 21:32:30
I won't have to paint the speakers again, however I do have to polish the finish once the paint sets up properly. I also have to pick up the legs for the right and left. I decided to go with the same speaker legs that come on the Yamaha Soavo 1PN. I can order them from the Yamaha parts site and with new spikes they'll get the speakers up high enough for the ports to work their magic. I don't have enough money to order them right away, but I do plan on getting them ordered sometime this month. I also am waiting on some new surround sound speakers to arrive, I'll post updates when I get a chance to give them a go.
New surrounds are in
Uploaded Dec 08, 2009 01:41:15
They are the Paradigm ADP-390's. Using a new camera too, after the death of the last one.
Uploaded Dec 08, 2009 01:41:17
Uploaded Dec 08, 2009 01:41:19
Uploaded Dec 08, 2009 01:41:22
Uploaded Dec 08, 2009 01:41:28
Uploaded Dec 08, 2009 01:41:33
Having some fun with the new camera.
Uploaded Dec 08, 2009 01:41:40
Uploaded Dec 08, 2009 01:41:42
Uploaded Dec 08, 2009 01:41:44
Uploaded Dec 08, 2009 01:43:25
Uploaded Dec 08, 2009 01:43:28
Just taking a few shots with the new camera. Looks a lot cleaner the my last one.
Materials for risers
Uploaded Dec 17, 2009 03:44:13
Starting work on the risers for the front speakers. You might be wondering why risers over traditional speaker stands. The big reason is because risers help isolate the speakers from the vertical room modes better then stands will. This isn't really an issue for smaller speakers, but for ones that can hit lower hrz it can be a nice upgrade.
Uploaded Dec 17, 2009 03:44:16
I'm making them very wide to allow me the most flexibility on speaker positioning.
Uploaded Dec 17, 2009 03:44:21
Well braced with the spare 2x12 and insulated for sound.
Uploaded Dec 17, 2009 03:44:23
Please no comments on my carpeting skills or lack there of, lol...
The end result
Uploaded Dec 17, 2009 03:44:29
Right speaker riser
The end result 2
Uploaded Dec 17, 2009 03:44:33
Left speaker riser
Finished with the risers
Uploaded Dec 17, 2009 03:44:38
To get the tweeter even with my ear level I needed to raise the speakers about 15-16 inches. The risers get them about 13 inches higher and once my feet for the speakers arrive I'll have them up another 3" (need bottom port clearance). I know they don't look amazing, but I've always operated under the principle that ascetics come secondary to acoustics. I can tell you they make a big difference, not subtle in your mind changes. After finishing the first riser we tested it out, and it was like all the sound was coming from one side of the room. You could hear faint noises from the other speaker but the difference in volume and bass celerity made it even hard to hear the other speaker. I've said this before, but I have to mention it again. Positioning is one of the single most important things you can do with your speakers. Even if you do nothing else, make sure you position your speakers correctly. Right now my front left and right form an equilateral triangle from the center listening position & the tweeters are lined up 3" short of my ears (will be dead on shortly). P.S. The second subwoofer (Rythmik F15) is still in the process of being saved for, holidays are putting a strain on my budget so it's been slow going.
#2 IS HERE!
Uploaded Feb 04, 2010 02:31:07
Warning, the following shots may be unfocused from an excess of dancing.
98 pounds of pure bass
Uploaded Feb 04, 2010 02:31:12
Can't wait to hook the sucker up.
Uploaded Feb 04, 2010 02:31:16
I broke out the SPL meter and checked the levels. Took a little while to tune them to match the fronts. Tuned them both ~6db less then the front speakers then the sum would bring them up ~6db.
Uploaded Feb 04, 2010 02:31:18
I spent the better part of the night they arrived in a trance listening to all sorts of instrumental music from around the world. It really made a huge difference in the room. The bass is more uniform and encompassing. It doesn't feel like all the bass is coming from a single side of the room anymore. In the future I do plan on refinishing both of the subwoofers to match my fronts. That however will be well down the line.
Time to get to work!
Uploaded Feb 06, 2010 22:28:48
2 months have finally passed and the paint has cured enough for me to start the polishing process. The tools I will be using is, 2000p sand paper, a rubber sanding block, Farecla G3, some terry cloths and 3M's car polish for dark finishes.
Tape up the front of the speaker
Uploaded Feb 06, 2010 22:28:55
I'm going to be wet sanding so I want to make sure I don't get any water near the drivers. I also don't want to ruin the finish on the front of the speakers.
Uploaded Feb 06, 2010 22:28:57
I decided to test the process on the back of the speaker first just in case. I'm going to sand it down a little and then try polishing it to see how the results come out.
Uploaded Feb 06, 2010 22:28:59
Left 1/2 sanded, right 1/2 sanded and semi-polished. Just to give you and idea of the pre and post results. This isn't fully polished, just a couple layers of the cutting fluid.
Uploaded Feb 06, 2010 22:29:01
Polishing the side
Uploaded Feb 06, 2010 22:29:03
All of the sanding and polishing I'm doing by hand.
Uploaded Feb 06, 2010 22:29:05
Almost done, just need the final layer of car polish.
Before and after
Uploaded Feb 06, 2010 22:33:10
Here is a side by side with my unpolished left speaker. Just to give you an idea of the before and after. I really couldn't be happier with the results. It took about 12hrs to do one speaker, but it was worth the effort.
Finished the polish on #2
Uploaded Feb 10, 2010 12:59:44
I didn't get a tripod, but I was able to find an angle where I could set the camera on the coffee table to steady it. The clerity of the reflection is amazing. Almost no ripples and you can make out even the pioneer logo (tho you might have to see the full sized image to see that). I might post another image later, but I'm EXHAUSTED.
Uploaded Mar 26, 2010 21:17:56
You should be able to make them any dimension. My risers are about 20"^3. You obviously need 6 sides, and 1 larger piece of the top. A single sheet of 3/4th MDF at your local home depot will build 1 the size of my riser with plenty of left over. Have the people at home depot cut the MDF down into manageable sizes, make sure to leave buffer because they aren't always the most accurate cuts.
Cutting down to size.
Uploaded Mar 26, 2010 21:17:58
Start by cutting the 6 pieces of MDF that will make up the cube to the right size and angle. Most table saws have a 45 degree angle option.
Uploaded Mar 26, 2010 21:17:59
You want to cut the area to open up the area below the woofer. With 4 of the 6 sides of the cube, cut a square out of the center. When doing this it is a good idea to raise the saw all the way up.
Uploaded Mar 26, 2010 21:18:00
This is a comparison between using the saw all the way raised vs. just enough to cut through the material.
Uploaded Mar 26, 2010 21:18:01
Gluing everything together
Uploaded Mar 26, 2010 21:18:03
I used a pin nailer to hold everything in place after it was glued and clamped, but if you don't have one you can just use wood glue and clamps. A 90 degree clamp is very useful here, just make sure you get one that is deep enough to clamp on to the 45 degree edges.
Uploaded Mar 26, 2010 21:18:06
Attaching the trim
Uploaded Mar 26, 2010 21:18:07
You really need a miter saw or box for this section. Cut the trim to fit the cabinet and attach with glue (or glue and nails). More to come soon...
A little wood filler
Uploaded Mar 28, 2010 07:44:23
For all those that aren't adept at woodworking (myself included), a little wood filler is a must on those pesky gaps. A nice sanding to smooth everything out and you're ready for the stain or paint.
Uploaded Mar 28, 2010 07:44:24
I have a very vibrant red stain that I used on my speakers I'll be using a little of. Paint also works but takes a lot more time to achieve a quality finish.
Uploaded Mar 19, 2010 03:05:25
A nice coat of a glossy clear coat to give it a nice appearance.
The top is on
Uploaded Mar 21, 2010 03:03:07
Put the leather top on.
Grill cloth is on, foam is attached
Uploaded Mar 22, 2010 00:01:18
Almost done now, just gotta fill the space with low density fiberglass. The grill cloth is attached with thing strips of wood that were nailed in place. On the last opening I plan to make an insert that I can use to get access to the insides later.
Uploaded Mar 22, 2010 00:01:20
Poofed out the fiberglass and built the door. Fits on quite snug. I wrapped string around the corners to get it in place then just pulled the string through.
Uploaded Apr 02, 2010 08:20:48
Finally finished the second riser. Now with both done it's time to calibrate!
Before and after riser
Uploaded Mar 05, 2010 19:42:42
This is with 1 sub, 0 digital correction (so no EQ's or PEQ's), crossover @80hz & the position of the sub is about the same (I eyeballed it). The dip at 65 is likely the vertical node, and the overall DB increase is because I brushed the gain knob lifting that sucker onto the riser. Blue is before, red is after.
PEQ & Calibration hardware
Uploaded Feb 15, 2010 11:32:24
Most of the hardware has arrived, just waiting on the USB midi device used to push the filters from the calibration software to the BFD.
Hooking up the PEQ
Uploaded Feb 15, 2010 11:32:26
In the mean time I'll be getting the hardware ready for when the last parts needed for setup arrive, which will be this week.
Hooking up the mic preamp
Uploaded Feb 15, 2010 11:32:28
Uploaded Apr 02, 2010 08:27:54
With the risers in place and the position of the subs settled I can finally begin applying a little digital correction. I still have lots of plans for room treatment in the near future, but for now I'll digitally correct what I can and benchmark the results. This will will have to wait a few more days tho, as I have a new preamp coming in soon.
Uploaded Apr 08, 2010 04:42:49
The new receiver arrived. I have experience with Integra pre-amps so the setup is identical short of a few minor differences. I was considering picking up some external amplifiers to use, but after giving it a shot I decided to stay with the internal amps until I finish building my replacement front speakers later this year. Until then I think my money is better spent on acoustical treatments and a better quality power conditioner. The calibration is finished for now. There is still a lot of storage in the room below 35hz, it decays down about 30db within the first couple hundred MS, then stagnates. My goal this summer is to design and build several LF dampening systems that'll increase the decay <120hz with out overly impacting the mids and highs. The designs for them are still in the trial stages, so until then my next DIY project will be simple dampening panels for the mains, but I'm considering a twist to the traditional design. I haven't decided if I plan to execute it tho, it would require a lot of space I don't have.
The build on the new diffusion & absorption array for behind the main listening position.
Uploaded Aug 31, 2010 15:31:27
I wanted to add some diffusers to the room, but from my experience they place an unwanted emphasis on the mids and highs. I decided to correct for this by using several smaller diffusers and alternate them with dampening. I wanted a fairly low target frequency for the diffusers, but I would be unable to achieve that with the given period width. I've corrected for this by placing the other diffusers within ½ a cycle of the highest frequency that was cutoff due to period width. To prevent repetition effects I used alternate functional permutations for each of the 4 diffusers by varying the primitive root value. The listening position will be too close to be completely effective, but I'm building it anyways knowing that most of the acoustic treatments I build will carry over to my next theater, which will be large enough to accommodate it. I tested a few models using specular reflections and it seemed to produce intended results, and consulted a few acoustical engineers I decided to press forward.
Now on to the build process: I started with the frame.
Uploaded Aug 31, 2010 00:04:06
Uploaded Aug 31, 2010 00:04:07
Uploaded Aug 31, 2010 00:04:09
Uploaded Aug 31, 2010 00:04:10
One diffuser down!
Uploaded Aug 31, 2010 00:04:12
Uploaded Aug 31, 2010 00:04:13
Finally. Took about a day per diffuser, all the cuts were made within +/-1mm.
Uploaded Aug 31, 2010 00:04:14
Cut holes to increase the effective surface area of the dampeners.
The Wood Dye
Uploaded Aug 31, 2010 00:04:16
I didn't have enough of my usual wood stain to finish this project so I decided to try something new. Instead if just using a wood stain, I'd use a dye, and apply a stain over top. I tested it on a sample that I liked and decided to give it a go.
Uploaded Aug 31, 2010 00:04:17
This is after the wood stain was applied, I was happy with the result.
The Clear Coat
Uploaded Aug 31, 2010 00:17:55
The clear coat is finished. I'm thinking about how I want to finish the diffusers, but I don't know what color would look best. I'm gonna hold off until I can see the near finished product in the room before I decide how to finish the diffusers.
Applying the fabric
Uploaded Aug 31, 2010 00:17:57
I don't like the look of dampeners that just coat the fabric over the top of the wood. It takes a lot more work to make it look nice attaching the fabric on the inside, but the end result is much better in my opinion.
Applying the fabric
Uploaded Aug 31, 2010 00:17:58
To keep the fabric taught I cut some thin strips of balsa wood to keep the tension on. It's rigid enough to keep the fabric in place and very easy to work with. It's soft enough that any normal staple gun should go through and it doesn't shatter when stapled.
Uploaded Aug 31, 2010 00:17:59
Adding the insulation to the dampening cavities.
Uploaded Aug 31, 2010 00:18:01
With the backing on the dampeners, everything is almost complete.
Uploaded Aug 31, 2010 00:18:02
The array is nearly finished, I still need to decide how to finish the diffusers, but I'll put that on the back burner until I have a little more time.
Uploaded Aug 31, 2010 00:18:04
Mounted it from the ceiling and placed it about the width of the dampeners from the wall to increase the effective range of the absorption.
Uploaded Aug 31, 2010 00:18:05
Unfortunately I ran into a hiccup with the mounting, the diffuser is ~3 inches off center. I'll have to adjust the mounts and the cable length to correct this, but that'll be for another day. Tonight I'm gonna take a break and watch a movie.
Uploaded Sep 11, 2010 02:24:50
The process on the panels is the same for the ones I used with the diffuser, only require a lot less work.
Uploaded Sep 11, 2010 02:24:51
Tossing the frames together, I use wood glue and brackets.
Uploaded Sep 11, 2010 02:24:53
Just increasing the usable surface area of the panel. With the thin cheap wood I used I decided not to make them too frequent for fear of impacting integrity.
Uploaded Sep 11, 2010 02:24:54
I used the same products and process as the diffuser, so I thought I'd spare the details. If you have any question about how to achieve this finish I'm more than willing to help answer some questions. Because they are just panels I'm tossing up on the walls I didn't to a ton of sanding, with a lot more effort you can make the finish look much better.
Uploaded Sep 11, 2010 02:24:56
Same as before, just using thin cuts of balsa wood and a staple gun to secure the fabric. Takes more effort but I prefer the results to fabric wrapped around the frame.
Uploaded Sep 11, 2010 02:24:57
Just like the last ones I fill them with insualtion, OC703, 705 or Rockwool. I personally use a lower density fiberglass to get a little better LF absorption from sympathetic resonance at the cost of mid and high end absorption.
Uploaded Sep 11, 2010 02:24:58
I really like the results of the stain, it almost glows in normal lighting situations.
Uploaded Sep 11, 2010 02:25:00
Uploaded Sep 11, 2010 02:25:01
Uploaded Sep 11, 2010 02:25:02
They are mounted the thickness of the panel from the wall to improve low end absorption.
Finished with those
Uploaded Sep 11, 2010 02:32:17
Ignore the window, I'm doing some work on it. I'm in the middle of building a huge bass trap, twice as thick and much larger that'll be suspended from the ceiling above the subwoofers. It should be done in a few days. After that I'll be building some membrane resonators for the corners. I'm planing to have both of those projects finished before the end of this month!
Uploaded Sep 13, 2010 21:43:33
The start of the bass trap that will be mounted in the area above the subs.
Uploaded Sep 13, 2010 21:29:01
Uploaded Sep 13, 2010 21:29:02
I'm getting better at getting the fabric to turn out nice. I've had a lot of practice by now, lol.
Uploaded Sep 13, 2010 21:29:04
A comparison with my other puny panels. Twice as thick, and much larger all around.
Uploaded Sep 13, 2010 21:34:51
He's keeping watch over the subs to make sure they don't get out of line. Now on to the corner membrane resonator! I'm still in the design phase, I have a good idea of how I want to build it but I'll need more supplies and some I can't get locally.
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