M-21 Giveaway Build Pics - Page 11 - Home Theater Forum and Systems - HomeTheaterShack.com

Old 03-09-10, 12:58 PM Thread Starter
Senior Shackster

corock

Join Date: Sep 2009
Posts: 348
re: M-21 Giveaway Build Pics

Quote:
Ricci wrote: View Post
I'm curious. How do you plan to smooth out the area around the driver flare out from individual angles into a smooth continuous curve?

Well, where the layers meet represents the outer edge of the circle. I'm going to glue the layers together from the middle out; by doing that I can temporarily stop putting the box together once I reach the top and bottom of the curve. That will leave me room to work on those individual angles without those three square pieces on the top and bottom getting in the way.

In theory, I'm going to take down those angles with a wood rasp until its close enough to work on it with a sander. I say in theory because I've never done this before. If anyone has worked on something similar and has some knowledge to pass on I would welcome it.
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Old 03-09-10, 01:18 PM
DerekG

Join Date: Apr 2009
Location: Conway
Posts: 177
re: M-21 Giveaway Build Pics

You might be able to find someone to cnc them into shape for you. Or at least close to it so the sanding is easier.
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Old 03-09-10, 01:43 PM Thread Starter
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corock

Join Date: Sep 2009
Posts: 348
re: M-21 Giveaway Build Pics

A friend of a friend has a shop with a cnc. I'll have to check into that. thanks.
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Old 03-11-10, 02:59 PM
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Josh

Join Date: May 2007
Location: Louisville, KY
Posts: 2,431
re: M-21 Giveaway Build Pics

Quote:
corock wrote: View Post
Well, where the layers meet represents the outer edge of the circle. I'm going to glue the layers together from the middle out; by doing that I can temporarily stop putting the box together once I reach the top and bottom of the curve. That will leave me room to work on those individual angles without those three square pieces on the top and bottom getting in the way.

In theory, I'm going to take down those angles with a wood rasp until its close enough to work on it with a sander. I say in theory because I've never done this before. If anyone has worked on something similar and has some knowledge to pass on I would welcome it.
Ahhh. That makes sense. The straight pieces will simply not be there yet. You may want to look at the cnc option as it'd be easiest by far. Perhaps a band saw could be used to remove most of the excess prior to sanding? Or perhaps a stationary belt sander. EDIT Actually after looking at the pics again I don't know if either of those would work well. What about using Bondo or something to fill in the circle instead?
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Old 03-11-10, 04:00 PM Thread Starter
Senior Shackster

corock

Join Date: Sep 2009
Posts: 348
re: M-21 Giveaway Build Pics

I want to stay away from bondo as my intention is to finish the box so that the plys and grain are visible.

I'm going to see what kind of damage I can do to those points with a chisel. I'm going to have the boards out seperatley to cut out the middle part, so if its efficient I might just chisel that area down to an easier dimension to sand.

The project is in a bit of a time-out right now as I figure out some of the semantics and wait for my circle jig to arrive in the mail. I can't start cutting out the middle part of the layers until I determine how thick the front of the box will be. That will be determined by what depth I'm going to mount the driver at, and I need the circle jig to experiment before I make a final decision on that.

I have a visual of what I want to accomplish, but I've never done this before so a lot of it is trial and error. However, There is no room for error on the box itself so I have to test some of this stuff on scrap before I implement it. If I mess up cutting out the hole I waste 6 sheets of plywood and a whole lot of time and effort.

ps. the friend of a friend has a cnc lathe. Not what I'm looking for.
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Old 03-11-10, 05:40 PM
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Mike

Join Date: Nov 2007
Location: San Dimas, CA
Posts: 1,633
My System
re: M-21 Giveaway Build Pics

I was thinking maybe you could use something like the Bosch 1250DEVS which has a Turbo mode which essentially turns off the random orbit for aggressive removal to do the edges?
I actually have one on the advice of a friend and it really works well even though it is expensive.

Last edited by sub_crazy; 03-11-10 at 10:00 PM.
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Old 03-11-10, 09:40 PM Thread Starter
Senior Shackster

corock

Join Date: Sep 2009
Posts: 348
re: M-21 Giveaway Build Pics

I did some work on how to take down those big edges.

This shows the area I have to take down. The triangular area in the rear is where things get weird because thats where the curve of the cone, the bend in the box wall and the veritcal wall of the box all intersect.

The chisels work pretty good taking down the edge to an angle closer to the actual curve.

The chisels will actually be necessary once I get into the area of the two forms intersecting. I'm actually going to have to carve that area and blend the different angles into each other.

Apparently I'm a sculptor now. I think it will be easier to do it once the box is glued together so that I have a better reference and can see the shapes taking form.

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Old 03-13-10, 04:52 PM
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Looney

Join Date: Sep 2006
Location: Topeka, KS
Posts: 430
My System
re: M-21 Giveaway Build Pics

Wow, once you get it rough shaped, you're probably going to have to do a lot of block sanding by hand. Maybe setup a cheap TV in your garage/outside, put in a movie and start sanding? Switch hands though, other wise you'll have one arm bigger than the other :-)
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Old 03-15-10, 01:04 PM
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Josh

Join Date: May 2007
Location: Louisville, KY
Posts: 2,431
re: M-21 Giveaway Build Pics

Good luck with the Michaelangelo technique.

Next time you should try something more challenging.
Ricci is offline
Old 03-15-10, 02:45 PM
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Michael

Join Date: Jan 2010
Location: Milford PA
Posts: 105
re: M-21 Giveaway Build Pics

Maybe next time you could carve the box out of a 3 ton piece of granite?
I can’t wait to see the end result. It’s going to be a monster.
gmichael is offline

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