Dedicated to Really Cheap Audio Enthusiasts
Much was learned from this project. This uses an off-the-shelf subwoofer crossover, don't ask me which part number. I used 5-way binding posts for the L and R inputs, and cheezy spring-loaded jobs for the satellite outputs.
<<updateMarch 2001. I found the invoice. The xover is MCM # 50-1445 and the sub is MCM #1455. The sub is still available but the xover is discontinued>>
The box is 3/4 MDF with all the joints gusseted with oak and MDF pieces. I used a 2" brad nailer during assembly, which made it realtively easy to align the pieces well and keep them in alignment without much fuss.
The enclosure was designed using online software, I forget which one. The box was designed using Visio 2000, including a cut list.
The coolest thing I did with this is the way I flared the port. The port is a 3" diameter piece of ABS 8" long. Where the port exits the enclosure is a double thickness of MDF. The first piece was cut to snugly fit the outside of the ABS pipe. The outside piece of MDF was drilled at about 2" diameter.
I used caulk to attach the ABS pipe during assembly. After all the glue and caulk dried I used a flush trim bit in the router with a guide bearing a the bottom to exactly align the hole through the MDF with the interior diemeter of the ABS. Then a 1/2" round over made a nice looking (and sounding) flare.
The worst thing I did with this was sealing everything inside. I would have to saw through the side to replace the driver or tweak the crossover. Using a passive crossover was a mistake. I will bi-amp all my speaker from now on. Also, I put fiberglass batting in the front, vented chamber. Most everything I read says not to put any damping material here.
The results? Don't ask me, I'm not too critical. When I first used this with the Anatomy speakers on my home page I smile alot. I guess that's what it's all about. It is now part of my permanent setup (until I build a better one), and is used with the low cost satellite speakers.
