Otto's IB ~~ Coming Together (w/ pics)

**Otto** · **10-29-06, 09:21 AM**

Quote:

jagman wrote:

Otto... sorry for taking your thread OT.

Bruce... after I get home I'll check my filters. I'll then post a response in my BFD/soundcard thread.

Hey, no problem, jagman. I'm glad the boost-at-20-Hz thing came up. It helped me out!

**Otto** · **11-02-06, 06:01 PM**

Hi there,

So the IB has come together nicely, frequency response is looking pretty good and both movies and music are sounding full. But there's one final piece for which I've been searching -- a grille that will cover the floor, and which fits the criteria of being 1) simple, 2) strong enough to stand on (even though it's in a low traffic area), 3) paintable if desired, and 4) being of a design that I like.

I hit Home Depot and Lowe's, of course. The only thing big enough to fit the 19.0" x 14.5" throat were return vents, and those are 1) not really good looking to me and 2) definitely not strong enough to be stood upon. I found some stuff at a website called Kees, and after working with one of the distributors in my area, I was offered a price of $310, shipped to my house.

It was nice, but it just got to be too expensive (more than the amp, almost as much as the drivers+shipping!).

So I took matters into my own hands... Last night from 8:30pm till 2:30am, a friend and I built something that I think will work. He owns a machine shop that makes all kinds of cool stuff for a wide variety of customers and purposes. It started as a piece of 3/8" aluminum, and turned into a pretty neat grate, customized for my IB's opening. These pics show the processing; I'll have to get some pics of the finished product tonight or tomorrow. As I didn't have a real camera with me, I used my phone and then emailed them to myself; I've never had a need to do that before. They picture quality isn't the best, but it's not bad either; it was a great convenience for sure.

We used a Haas CNC milling machine. It's an impressive device that can "cause great bodily injury" -- and presumably death. Even though it got to be quite a late night), we both came out with all our fingers.

Enjoy!

**jagman** · **11-02-06, 06:57 PM**

Very cool! Goes along well with the idea that an IB is a custom sub.

**SteveCallas** · **11-02-06, 09:51 PM**

Very nice!

Instantly reminded me of the metal grate floors in Aliens, when Hicks has to cut through one in a hurry to get to Newt in the sewer. Anybody know what I'm talking about?

**Otto** · **11-02-06, 10:40 PM**

Thanks guys! I haven't seen Aliens, but I have an idea of what you are talking about. It reminds me of a paper mill I used to work at in college. They had lots of metal grates, stairwells and catwalks.

Here's a few more pics of the completed project in its final resting place, although not screwed down.

**Sonnie** · **11-02-06, 11:34 PM**

That is awesome Otto... wow! I'm impressed. That's a serious grill cover there.

**WillyD** · **11-03-06, 01:35 AM**

Man Otto, that grill is sweet!

**technimac** · **11-03-06, 02:05 AM**

Otto,
Excellent work!

That's gotta be the best-looking custom grill I've ever seen...

...But you better watch out, other forum members may be requesting these from you in the future

Your cell phone does take pretty good pictures...I like the one showing the milling in progress.

Now, I hope the IB makes all your work worthwhile!

Cheers, Bruce

**jagman** · **11-03-06, 01:12 PM**

It is very nice. The aluminum has the contemporary look, too. Well done!

**mrogowski** · **11-03-06, 01:15 PM**

That's totally A1!!!! I love it! Thanks for posting the pictures of that machinery - sure is interesting.

Gee, now that I think about it, I wish I had friends like that...

Best,
Mark

**SteveCallas** · **11-03-06, 03:23 PM**

Yes, that is extremely nice work.

**technimac** · **11-03-06, 04:29 PM**

Otto,
The last close-up shows what seems to be a sand-blasted/etched finish (is that correct?). It looks so good!

I also like the way you did the chamfers after the surface was finished - gives it even more of a "professional look".

Huge kudos to you and your buddy for a job well-done.

Cheers, Bruce

**Otto** · **11-03-06, 11:14 PM**

Wow guys, sounds like we got some good reviews on the grille!

Thanks so much for the compliments. I thought you guys might like it...

Quote:

technimac wrote:

...But you better watch out, other forum members may be requesting these from you in the future

Well, I told my buddy that there might be a little market for these things. He said he can make more, but they're not necessarily cheap. But if anyone's interested, PM me and I can get you in touch with him. I gave him $100 for it, and feel like I got a great deal (pun intended).

Quote:

technimac wrote:

Now, I hope the IB makes all your work worthwhile!

Overall, I'd have to say that the whole IB process has been extremely gratifying. For the price, I'm not sure it can be beat. It's also fun to actually create something. For anyone who's willing to cut a hole in their floor, ceiling or wall, I fully encourage them to consider IB!

Quote:

technimac wrote:

The last close-up shows what seems to be a sand-blasted/etched finish

Actually, to get that finish all we did was use a rotating orbital sander on the bare aluminum. It only took about two minutes. Initially, I was going to paint it to match the carpet, but I think I'm going to leave it as-is. I will probably line it with regular ol' grille cloth material on the backside so that you can't drop coins and toys and whatever into the hole. I don't want to have to unscrew it all the time to clean up the inside. But since it's screwed down, it shouldn't rattle at all, which is cool.

Anyway, thanks again for all the nice comments, and have a good night.

**Bent** · **11-04-06, 12:49 PM**

It looks like a million bucks...
Does it flex at all when you press on it?

**Otto** · **11-04-06, 01:05 PM**

Quote:

Bent wrote:

It looks like a million bucks...
Does it flex at all when you press on it?

Thanks, Bent!

Maybe just a bit if I stand on it (at 200 lbs). But that may just be it compressing into the carpet and pad. It's pretty dang stout.

**Chrisbee** · **11-04-06, 01:20 PM**

It really is a work of art.

**azjimmy** · **11-05-06, 12:47 AM**

Thanks for posting those pictures. It took me back to when I worked in a machine shop. Those CNC machines are almost hypnotic to watch, and the smell of coolant stays with you for days.
Nice work on the IB. I am really wanting to start a project like this someday.
Jim

**mrogowski** · **11-05-06, 10:56 AM**

I'm with you Jim. If only there was a way to convince the Mach 5 'CEO' that this was the way to go, I'd do it.

m

PS: Noticed Charlie's quote in your sig - are you a home brewer?

**azjimmy** · **11-06-06, 03:54 AM**

Quote:

mrogowski wrote:

PS: Noticed Charlie's quote in your sig - are you a home brewer?

Yup, but not recently. I haven't brewed since I had a relapse of my back problem. I need to find an assistant to lug my full kegs and carboys around, but no takers yet.

I am enjoying a high gravity (11%!) holiday brew from 2004 right now. It was my fist attempt at cask conditioning. Nice and smooth. I'll be sad when it's gone.
Jim

**Owen Bartley** · **11-06-06, 06:51 AM**

Wow Otto, that looks really really good. I love how DIY projects can get such incredible results by calling in a favour or two, and have friends in the right places. Great job.

**kano32** · **11-06-06, 04:22 PM**

Otto,

Would you recommend the Mach5 driver's? I have been thinking about an IB but my budget is really limited. I wouldn't mind some Soundsplinters but at $250 a piece, ouch. Anyway, great j

Advertisement