Custom 3-way horn - Home Theater Forum and Systems - HomeTheaterShack.com

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post #1 of 61 Old 04-02-10, 01:14 PM Thread Starter
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Custom 3-way horn

Here is a quick rundown on the build of the speakers I use in my 2-channel rig. This is the second version. The previous were corner horns with JBL guts.

First some MDF and Baltic birch to build the skeleton.

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post #2 of 61 Old 04-02-10, 01:16 PM Thread Starter
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Re: Custom 3-way horn

Here is a closeup of the four layers of kerf MDF that make up the sides. I have filled it with glass beads used in bead blasting. This stuff is finer than sand and pours like water.

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post #3 of 61 Old 04-02-10, 01:18 PM Thread Starter
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Re: Custom 3-way horn

Here I'm starting to veneer the cabinets with sapele pommele. I used Heat Lock glue that you roll on and let dry. I then afixed the veneer with a steam iron (don't tell the wife).

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post #4 of 61 Old 04-02-10, 01:19 PM Thread Starter
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Re: Custom 3-way horn

The cabinets veneered and the front baffles painted with a textured grey paint.

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post #5 of 61 Old 04-02-10, 01:21 PM Thread Starter
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Re: Custom 3-way horn

These are the feet I machined from some 6061 billet aluminum bar, cut it into 4" slugs and trued up on a metal lathe. There are three per speaker. They had to be able to handle the 300+ pounds per speaker.

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post #6 of 61 Old 04-02-10, 01:22 PM Thread Starter
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Re: Custom 3-way horn

Here is the finished speaker without the grill.

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post #7 of 61 Old 04-02-10, 01:24 PM Thread Starter
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Re: Custom 3-way horn

Here is the same speaker from the back showing the open back for the Altec 511B horn with the Altec 802-8G driver. The blue bag around the throat is 2 1/2 pounds of lead shot.

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post #8 of 61 Old 04-02-10, 01:30 PM
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Re: Custom 3-way horn

Beautiful work.
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post #9 of 61 Old 04-02-10, 01:35 PM Thread Starter
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Re: Custom 3-way horn

Quote:
dyohn wrote: View Post
Beautiful work.
Thank you. They are a labor of love.

By the way, I used the image button to insert the pics. It is using the cap IMG tag.
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post #10 of 61 Old 04-02-10, 01:42 PM Thread Starter
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Re: Custom 3-way horn

Here is a picture with the grills on. They are made from a metal mesh covered with some JBL blue grille cloth.

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