Epik 15" DIY Ported Subwoofer - Home Theater Forum and Systems - HomeTheaterShack.com

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post #1 of 55 Old 06-08-12, 07:39 PM Thread Starter
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Epik 15" DIY Ported Subwoofer

Background:

I've been itching to build a DIY subwoofer since I purchased the Epik Valor in early 2008. The Valor is a quality sealed 15" design with a 350W BASH amp. It has served me well since I bought it but I've always been interested in the extra output and extension offered by a ported design. I had wanted the Knight at the time of purchase but the wife shot it down due to size (now it's time for payback ). I started to investigate purchasing a new driver and amp, thinking I might sell the Valor to subsidize the build.

Ultimately, I decided to design and build a new ported enclosure and transplant both the Epik 15" driver and amp into the box. As some may recall, Chad used to sell the Valor, Knight, and Caliber models in different enclosures but using the same driver and amp combo. So, in effect, what I am building is equivalent to something between the Knight/Caliber in size and tuning frequency. I e-mailed Chad my plans (including the below Sketchup drawing) and he blessed the project saying the performance should be excellent. While he didn't provide the T/S parameters of the driver, he did indicate the driver has 27-29mm Xmax (one-way) and the plate amp has a HPF at 20Hz as well as a boost at 20Hz.

The Valor is currently used as an end table at the end of my couch. The new ported enclosure will occupy the same space and has been sized to fit in this spot.

Here is a pic of the Valor in its current home:
Epik 15" DIY Ported Subwoofer-valor1.jpg

Here is a pic of the 15" Valor driver:
Epik 15" DIY Ported Subwoofer-epik_driver.jpg

Enclosure Specs:

Driver: Epik 15" Valor/Knight/Caliber
Box Dimensions: 20"W x 24"H x 28"D
Port Dimensions: 12"W x 2.5"H x 35"D
Box Volume: 5.1 cf
Tuning Frequency: 20Hz
Amp: 350W plate amp (HPF @20Hz)

For comparison, the Valor enclosure is 16.5"W x 22"H x 21"D.

Here is the Sketchup drawing I used to create the cutsheet:
Epik 15" DIY Ported Subwoofer-ported15_skp.jpg

Build Plan:

The box will be made from MDF. The current plan is to use wood veneer to finish it with quarter-round around the front face. I'm not decided yet on the wood type but would like to stain match my TV stand.

I'll be gluing and screwing (I have minimal clamps and am impatient) using square-head trim screws as recommended in one of the sticky threads here.

I've made all the cuts and did a dry fit this week, all looks good. Panel cuts were made with a table saw. Circle cuts and framing cuts were made with a jigsaw.

Here are a couple of pics of the dry fit:
Epik 15" DIY Ported Subwoofer-box_dry1.jpg

Epik 15" DIY Ported Subwoofer-box_dry2.jpg


If all goes well, assembly of the box should begin this weekend.

Steve

Last edited by dboff01; 06-30-12 at 07:19 AM.
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post #2 of 55 Old 06-08-12, 08:54 PM
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Re: Epik 15" DIY Ported Subwoofer

That's looking very impressive already.
As for the staining I find to match another piece of wood you will need to keep all your offcuts and try it on them first.
Let me know how you get on as it can be tricky and there is an art in getting it right.
Feel free to pm me if you get stuck.

Cheers,
Bill.

Silence is golden but duct tape is silver.

DIY completed:

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post #3 of 55 Old 06-09-12, 08:33 AM Thread Starter
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dboff01
 
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Re: Epik 15" DIY Ported Subwoofer

Quote:
robbo266317 wrote: View Post
As for the staining I find to match another piece of wood you will need to keep all your offcuts and try it on them first.
Let me know how you get on as it can be tricky and there is an art in getting it right.
Feel free to pm me if you get stuck.
As I've never veneered or stained anything, I may take you up on your offer. Thanks.
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post #4 of 55 Old 06-10-12, 08:15 PM Thread Starter
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Re: Epik 15" DIY Ported Subwoofer

Only had a couple of hours of spare time today to start assembly, I'd say I'm approximately 1/3 complete.

First glued and screwed some practice pieces to get a feel for how much glue (Titebond) to use and how easily the screws would bite/recess. Started with too much glue, lots of dripping down sides. Settled on a practice of laying a bead and then gently dragging my finger across to evenly coat surface. Kept a wet rag handy to clean up any excess after each piece was secured. Used a handful of clamps (2 - 3' and 2-1' I picked up at Harbor Freight for cheap) to secure the work while I pre-drilled and inserted screws, the process worked very well.

As of now the L-port is fully built and secured to the bottom of the sub-woofer frame, and 1 side is attached to the bottom as well. In my haste I forgot I wanted to paint the port surfaces near the opening black before securing ... oh well I'll tackle that next. Also will add a bead of silicone to all internal seams while I still have access to them. I must say the square-head trim screws are a cinch to work with, don't slip and easily recess themselves, no need for countersinking.

Was so pressed for time today, no new pics taken, but I'll take some on the next building session. Hopefully prior to next weekend, but weekdays are always hit-or-miss for personal projects.

Steve

Last edited by dboff01; 06-14-12 at 07:05 PM.
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post #5 of 55 Old 06-17-12, 03:57 PM
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Re: Epik 15" DIY Ported Subwoofer

can you send me the sketchup file you have for the box?
i am working on building a ported box very similar to this.
thanks.
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post #6 of 55 Old 06-17-12, 05:56 PM Thread Starter
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Re: Epik 15" DIY Ported Subwoofer

Quote:
zeroxil wrote: View Post
can you send me the sketchup file you have for the box?
i am working on building a ported box very similar to this.
thanks.
The file is approximately 3MB and exceeds the allowable size for an .skp or I would have included in the 1st post. You don't have sufficient posts for a private message. Not sure the best way to make the Sketchup available to you or others ... anyone have suggestions?
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post #7 of 55 Old 06-18-12, 09:03 PM
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Re: Epik 15" DIY Ported Subwoofer

other than emailing the file as an attachment, i am not sure.
i dont know if posting email addresses is allowed.
you could try uploading to a file share site like dropbox or filez.
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post #8 of 55 Old 06-19-12, 10:37 PM
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Re: Epik 15" DIY Ported Subwoofer

Use the post padding thread located here to get to 5 posts - this should enable the PM feature (as well as many other site functions) - check out the top of the Zero Tolerance Rules for a comprehensive list.


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post #9 of 55 Old 06-22-12, 07:04 PM Thread Starter
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Re: Epik 15" DIY Ported Subwoofer

Had the day off and made a bit more progress. Port is painted black using Rust-Oleum flat black spray paint. Front inner baffle and rear wall are now also installed. Using silicone to seal all inner seams.

Here are some pics of the current progress.

Side, back, and port installed ...
Epik 15" DIY Ported Subwoofer-p1030026.jpg

Close-up of trim screw to show nice natural recess ...
Epik 15" DIY Ported Subwoofer-p1030028.jpg

Side shot with front inner baffle, side, rear, and port installed ...
Epik 15" DIY Ported Subwoofer-p1030035.jpg

And one more for good measure ...
Epik 15" DIY Ported Subwoofer-p1030038.jpg

Had to stop today because went to install quarter round at top of inner port opening and realized I only have 1/2" quarter round in the garage, need 3/4". Will have to make a run to the store tomorrow to pick it up.
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post #10 of 55 Old 06-23-12, 12:16 AM
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Re: Epik 15" DIY Ported Subwoofer

Great work so far. Its starting to take shape for sure.
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