Today I added a new sub woofer enclosure to my flat pack designs. This enclosure is 1.6 cu. ft. nominal, about 1.5 with 12″ driver, damping material and wiring and is suitable for a woofer from 8″ to 12″ in diameter either ported or sealed.
Construction makes assembly simple and foolproof with dado joints on back, front (optional) and sides. Top and bottom panels fit into dado cuts on front, back and sides so all joints are tight sealing double edge dado joints. Standard material is 3/4″ MDF unless you want 3/4″ plywood at a little more cost.
The enclosure features a dado set U brace around the sides and back to stiffen the enclosure which, when properly glued and attached, helps make that “tight” sounding sub woofer you’ve always wanted. An additional full wrap brace can also be ordered providing bracing in two dimensions (left and right plus top and bottom and back) rather than just one dimension. If the sub is placed on the floor with the brace oriented horizontally and spikes are used on the bottom, the extra bracing is unnecessary.
This latest project is another Dipole. These are baffles cut for an NaO Note II RS dipole speaker system. These are complex specialty baffles featuring front and rear routing and custom roundovers for both drivers and outside edges. The initial drawing was separated into front and rear view then toolpaths assigned to each side independently. I then had a choice to either chuck up a regular piloted roundover bit, hang it off the Z axis and use it like an upside down router table to cut the various roundovers, or to realign the baffles and use a CNC program to cut them. Continue reading
There are many places to purchase speaker boxes for your amateur home or automobile speaker project. Now there is one more. Live in or near the Portland Oregon area? You can now order and pickup directly here in town. If you’re not too far away I’ll even deliver.
TRB CNC makes hobbyist speaker enclosures and custom CNC signs, art projects and prototype parts in wood, plastic, soft metals or foam. Send me a drawing and I cut the parts. CNC is a very accurate way to cut wood, plastic or other materials that can be cut with a carbide bit. I’m focusing on speaker enclosures because that’s what I know best but I’m open to new ideas.
Building a Dipole kit? Need a custom baffle? This is the place to ask. I can layout and cut single or double sided baffles in MDF, high quality plywood or solid hardwood. By stacking hardwood planks together we can cut deep shapes into the baffle including waveguides, rear driver mounting roundover to reduce diffraction effects, dado corners for increased surface area, miter joints for seamless corners, even lock miter joints.
Is your project not so fancy and you just need a baffle with accurately place holes cut to exact dimension? Just ask. Send me a picture with measurement and I can usually cut to order in one day.
So, you bought a flat pack speaker box and want to know the best way to assemble it, or maybe it has gaps at the seams and you want to know why.
Since these parts are all cut on a CNC machine there is a possibility they may have tabs on the edges of some of the pieces. These tabs can sometime interfere with the joints of the enclosure making it appear as if the parts are not cut square. First thing you should do when you unpack the kit is brush all parts with a stiff brush paying careful attention to the inside corners of the dado cutout. Sawdust build up in this area can prevent the enclosure from fitting tightly and squarely.
Second is to check the inside ends of all rabbets. When the machine cuts it sometimes leaves tiny bits of uncut material at the inside of the corners. These, being on the assembly edge of the box, can also prevent a tight, square fit when assembling the box. I use a box cutter or razor knife to trim any excess material that might be left over on the inside of the dado cuts. Third, thoroughly clean all parts again with a stiff brush. I found a dry dish brush works very well for this. You want to remove any and all loose material but you don’t want to change the shape of the parts at all. The machine is very accurate at cutting the part out but sometimes it pack dust tightly into corners making square assembly difficult.Begin by laying out and identifying the parts.
- Front and Back are 11 ½” x 7 ½.
- Sides have rabbets cut around the outside edges
- Top and bottom are different sizes with Top being the smaller nearly square piece. Continue reading
After several discussions on various speaker building forums I’ve decided to offer flat pack speaker enclosures as an ongoing service. As my first offering I’ve designed a simple unfinished enclosure that can be quickly scaled to any volume with minimum effort. The enclosures will be made mostly from Plywood and MDF. The first group will be simple unfinished MDF flat pack enclosures just like those being offered at Parts Express. The biggest difference being that I can beat their price, mine ship faster and I offer custom driver openings. I can also offer custom baffles for waveguides, routing for flush mounted drivers, routing for rear mounted drivers, woofer waveguides (rear mounted woofer or midrange), round-over or chamfering inside or outside, and any other custom driver mounting option at reasonable rates. My initial boxes will be very similar to PE boxes in terms of simplicity. But, rather than assemble the enclosure around the sides as they do, my enclosures assemble around the back.
The back of the enclosure is a flat piece with a dado cut around the outside. The sides, top and bottom then assemble against the back to form the enclosure. Adding more complex joints is very easy using this technique and makes it much easier to produce a custom enclosure size since all parts are relative to the back dimensions except box depth. I can now offer custom sized unfinished enclosures in any volume up to about 8 cubic feet without having to charge for extra setup time. The client can calculate the dimensions based on my design. From there I can edit the part sizes, cut the enclosure parts and ship them off to the customer. Below is a short video showing the basic design used in construction. Continue reading