DIY 2 way Synergy speakers - Home Theater Forum and Systems - HomeTheaterShack.com

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post #1 of 35 Old 10-28-16, 10:59 PM Thread Starter
 
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DIY 2 way Synergy speakers

I have been wanting to make a full range horn loaded speaker for a while...so today I picked up 2 4x8' sheets of 3/4 MDF to do some testing. I will be starting with a 40" x 27 1/2" x 26" horn, and then adding some woofers to them after running REW on them. If they sound as good as I have heard they do, I will then make another one that is bigger. Luckily I have 3 spare EV DH1As to use for 3 new Synergy horns with multiple 15" woofers. I will post pics up as I progress.

Updatehe woofers are Eminence Kappa 15C woofers

Cost breakdown:
Eminence Kappa-15C... $109 each (2 required per speaker)
EV DH1A driver... $ I already have 3 spares (enough to do all 3 front speakers), but if I was to buy them used it would be around $100 each
Speaker connectors (2 sets per speaker)...$unknown as I had them laying around already
3 sheets 3/4 MDF... $150

Ron

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Last edited by ellisr63; 11-27-16 at 06:23 PM.
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post #2 of 35 Old 11-01-16, 11:45 AM Thread Starter
 
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Re: DIY 2 way Synergy speakers

Here is what we have so far.

Basic cabinet...




Rear shot of sides mocked up...


Front shot of sides mocked up...


Side panels with ports cut...


Ports with dimensions in the woofer cavity for reference later if needed.


Rear shot of cabinet with woofers installed...


Front shot of horn (still need to trim the horn down to the cabinet size)...

Ron

My Home Theater
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Last edited by ellisr63; 11-27-16 at 06:51 PM.
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post #3 of 35 Old 11-11-16, 02:17 PM Thread Starter
 
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Re: DIY 2 way Synergy speakers

I just got these in the mail today...




We are going to Burning Amp this weekend to see other DIY stuff, and hopefully will be able to start cutting wood next weekend.
Tonto and puukorva like this.

Ron

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post #4 of 35 Old 11-17-16, 08:56 PM Thread Starter
 
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Re: DIY 2 way Synergy speakers

We have decided to make the cabinets a little different as a friend has made them out of a K-402 horn...so what I am going to do is try to duplicate the box size of the one he is using, and then make my horn fit it. The new Synergy horn box will be 40" wide, 26" high, and 26" deep. I have the MDF for the horn ready to cut, and I am getting the MDF for the cabinet cut Friday or Saturday. Hopefully I will have some pics of a complete Synergy horn this weekend.

Ron

My Home Theater
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post #5 of 35 Old 11-18-16, 06:46 PM Thread Starter
 
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Re: DIY 2 way Synergy speakers

Today I got all of the MDF required for a single horn cut to rectangles, but 2 pieces still need to be cut to triangles, and 2 pieces need to have the front and rear edge bevel cut so it will be flush at the front of the cabinet, and flush in the rear to hold the compression driver. I also need to get 2 woofer rings cut. I have edited the first post with the new sizer of the horn, and will update with pics when I start to put it together.

Ron

My Home Theater
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post #6 of 35 Old 11-19-16, 06:58 PM Thread Starter
 
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Re: DIY 2 way Synergy speakers

Today we got the basic rectangular cabinet together, rear part holding the horn driver, and 2 sides cut, and angled. The horn is a 45 degree horn so far, and will extend beyond the cabinet a bit. The sides of the horn are 33" long. The dimensions of the box are 40" wide 27 1/2" high, and 26" deep. I am contemplating making a second section on the horn that will flare out maybe 6" more. From what I understand this will help the polar control of the lower end. By the time we got this far we ran out of time. Hopefully next weekend we can get it finished. I will take pics of the cabinet before we insert the horn inside. If all goes well it shouldn't be long before it is ready to test.

Gotta say this speaker is HUGE! I am assuming it will weigh around 200lbs as it took the better part of 3 sheets of MDF, and will have 2 15" woofers and a 30lb horn driver.

Ron

My Home Theater
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post #7 of 35 Old 11-19-16, 07:26 PM
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Re: DIY 2 way Synergy speakers

What! No pics now...what's up with that!!!
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post #8 of 35 Old 11-19-16, 08:38 PM Thread Starter
 
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Re: DIY 2 way Synergy speakers

Quote:
Tonto wrote: View Post
What! No pics now...what's up with that!!!
My friend had to leave and we were doing this build at his house, by the time we cleaned up it was too late. I will have pics when we work on it next weekend though.

Ron

My Home Theater
BenQ MH741 Projector, Yamaha CX-A5100, (2 pr) JBL 8340As, (2 pr) JBL 8320s, PS3, XBox One, (1) Asus Mini, Redmere HDMI cables, Monster Signature HTPS7000, (2) Furman Power Conditioners, (2) DTS-10 subs, SeymourAV 180 (195" diag) scope screen, Darbee Darcet,Yamaha P7000s, Oppo UDP-203

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post #9 of 35 Old 11-19-16, 08:43 PM Thread Starter
 
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Re: DIY 2 way Synergy speakers

One problem we are having right now is determining if we need to cut the triangle sides at a bevel or not. I say no, but my friend is still not sure. The sides of the horn are straight up and down and angled from the center at 43 degree toward the sides of the cabinet. I think that since the sides are straight up and down that the center triangle should not need its sides angled...even though the top triangle will be angled downward at the driver and the bottom triangle will be angle up to the driver.

Any ideas?

Ron

My Home Theater
BenQ MH741 Projector, Yamaha CX-A5100, (2 pr) JBL 8340As, (2 pr) JBL 8320s, PS3, XBox One, (1) Asus Mini, Redmere HDMI cables, Monster Signature HTPS7000, (2) Furman Power Conditioners, (2) DTS-10 subs, SeymourAV 180 (195" diag) scope screen, Darbee Darcet,Yamaha P7000s, Oppo UDP-203

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post #10 of 35 Old 11-21-16, 02:10 PM
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Re: DIY 2 way Synergy speakers

My guess would be no.
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