Hi Friends
I am back with another Project, a 3-Way design with P A Drivers again. This time also its all Beyma drivers. 18 Inch Sub, 8 Inch Mid & Ribbon Horn Highs (TPL 150). All drivers are Neo Magnet. The Bass Enclosure will be separate, The Mids & Highs will be in separate enclosure.
As usual I have modeled the enclosure in 3D software (Solid Edge ST6) so that I can get the exact volume which is required as per design.
I am not writing too much on the enclosure design. I will be sharing the built process. So below are the photos of same.
Panels cutted on CNC
![01 CNC Cutting.jpeg 01 CNC Cutting.jpeg](https://www.hifivision.com/data/attachments/48/48972-0fc022718d0a9d0f22266b7847bb60b0.jpg?hash=D8AicY0KnQ)
Even though all panels are cut on CNC, Remember the CNC also has its own tolerance error. A table saw can be very useful when you need to flush the panel my 1 mm or 2mm.
![WhatsApp Image 2021-09-04 at 9.19.32 PM.jpeg WhatsApp Image 2021-09-04 at 9.19.32 PM.jpeg](https://www.hifivision.com/data/attachments/48/48989-88a2e8c1169bad44ea093ab4d33022e7.jpg?hash=iKLowRabrU)
Front Baffle is double 25 mm HDMMR (HDF) total 50 mm thick, Glued with each other & clamped.
![02 Glue.jpeg 02 Glue.jpeg](https://www.hifivision.com/data/attachments/48/48973-de2fb71245f99341639cd8c3d1bacfe4.jpg?hash=3i-3EkX5k0)
![03 Clamp.jpeg 03 Clamp.jpeg](https://www.hifivision.com/data/attachments/48/48974-132a3d594a0195b1786a0ef94e887389.jpg?hash=Eyo9WUoBlb)
Getting the Frame ready, Sides Top & Bottom. These are screwed with each other,
![04 Frame TBS.jpeg 04 Frame TBS.jpeg](https://www.hifivision.com/data/attachments/48/48975-cf15dc5566537909f76553faf8daaac5.jpg?hash=zxXcVWZTeQ)
Front face of Mids & Highs Enclosure
![05 Mids & Highs Front.jpeg 05 Mids & Highs Front.jpeg](https://www.hifivision.com/data/attachments/48/48976-7902a3faf7abb865b5105ca7c92ee1c1.jpg?hash=eQKj-veruG)
Assembly of Bracing in Bass Enclosure
![06 Bracing.jpeg 06 Bracing.jpeg](https://www.hifivision.com/data/attachments/48/48977-ae21766b36390a93be54fad9f5ea7383.jpg?hash=riF2azY5Cp)
Felt used for lining internal walls of Bass Enclosure
![07 Felt.jpeg 07 Felt.jpeg](https://www.hifivision.com/data/attachments/48/48978-45581803454ea94590b51317d399c3c2.jpg?hash=RVgYA0VOqU)
Gluing of Felt with internal walls with fevicol (Marine). I forgot to mention the glue I am using is Fevicol Marine grade
![08 Felt Glue.jpeg 08 Felt Glue.jpeg](https://www.hifivision.com/data/attachments/48/48979-6dea1578fd0c38fb9433e07ac6e51365.jpg?hash=beoVeP0MOP)
Mid Enclosure assembly
![09 Mid Encl 2.jpeg 09 Mid Encl 2.jpeg](https://www.hifivision.com/data/attachments/48/48980-80159a9845269bd0450b2f1ebae42c6b.jpg?hash=gBWamEUmm9)
![09 Mid enclosure Assembly.jpeg 09 Mid enclosure Assembly.jpeg](https://www.hifivision.com/data/attachments/48/48981-c56e6980265fd18ebc4d5ea9b6dc5cb8.jpg?hash=xW5pgCZf0Y)
Vents Cutting & Gluing. I am using Finolex schedule 40, A 4" Pipe for vents. It is very thick and very strong. This Pipe diameter is big for my Miter Saw so i have to make 2 passes to cut the pipe throughout.
![10 vent cutting.jpeg 10 vent cutting.jpeg](https://www.hifivision.com/data/attachments/48/48982-88a5dbfefa1fad6197480481a87d8684.jpg?hash=iKXb_vofrW)
![11 Vent Glue.jpeg 11 Vent Glue.jpeg](https://www.hifivision.com/data/attachments/48/48983-4e994a676caf452223c8e636111b8f93.jpg?hash=TplKZ2yvRS)
And here is my new toy again "Makita RP2301FC" Router to make the Round-over on the Vents. Its a very Powerful Router with 3.25 HP of Power. The coll-et size is 12 mm. It has variable speed so I can control the speed, this feature is very useful while using big diameter bits. This Router is Beast, I didn't feel any load on this machine, it was running like a hot knife on Butter. It is also very heavy but when using it, it was very steady and very comfortable. The Plunge mechanism was the Best among the routers which i have used till date.
![12 Vent Radius.jpeg 12 Vent Radius.jpeg](https://www.hifivision.com/data/attachments/48/48984-27489258e7bc874b39f1b866bcbf4ec6.jpg?hash=J0iSWOe8h0)
The Radius of round-over is 19 mm. It just took 2 passes to get the job done. It is very difficult to do this radius with lower power rated routers.
![13 Vent Radius.jpeg 13 Vent Radius.jpeg](https://www.hifivision.com/data/attachments/48/48985-b69a7badd75ff7ce48856babf6fb40b0.jpg?hash=tpp7rddf98)
Assembly of Front Baffle, In Front Baffle I have not used screws, Its just glued, However the Back Panel is screwed with Sides Top & Bottom.
![14 Assembly of Top & Bottom.jpeg 14 Assembly of Top & Bottom.jpeg](https://www.hifivision.com/data/attachments/48/48986-afd8158d1acea90d55aa40fbb1f2ffe7.jpg?hash=r9gVjRrOqQ)
After gluing today I did sanding, The HDMMR sheet is very hard I had to use belt sander to sand the edges and then Orbital sander for smooth finish, After sanding I patched the holes of screws with sawdust and glue.
![14 Sanding with Belt Sander.jpeg 14 Sanding with Belt Sander.jpeg](https://www.hifivision.com/data/attachments/48/48987-2d80d2866e316d9c738d0e919c581e65.jpg?hash=LYDShm4xbZ)
![15 Filling up the Screw Holes.jpeg 15 Filling up the Screw Holes.jpeg](https://www.hifivision.com/data/attachments/48/48988-991dff5ea36d121173efe5f48dfa0f59.jpg?hash=mR3_XqNtEh)
This is the built journey till today. I will update this thread as i progress further.
I am back with another Project, a 3-Way design with P A Drivers again. This time also its all Beyma drivers. 18 Inch Sub, 8 Inch Mid & Ribbon Horn Highs (TPL 150). All drivers are Neo Magnet. The Bass Enclosure will be separate, The Mids & Highs will be in separate enclosure.
As usual I have modeled the enclosure in 3D software (Solid Edge ST6) so that I can get the exact volume which is required as per design.
I am not writing too much on the enclosure design. I will be sharing the built process. So below are the photos of same.
Panels cutted on CNC
![01 CNC Cutting.jpeg 01 CNC Cutting.jpeg](https://www.hifivision.com/data/attachments/48/48972-0fc022718d0a9d0f22266b7847bb60b0.jpg?hash=D8AicY0KnQ)
Even though all panels are cut on CNC, Remember the CNC also has its own tolerance error. A table saw can be very useful when you need to flush the panel my 1 mm or 2mm.
![WhatsApp Image 2021-09-04 at 9.19.32 PM.jpeg WhatsApp Image 2021-09-04 at 9.19.32 PM.jpeg](https://www.hifivision.com/data/attachments/48/48989-88a2e8c1169bad44ea093ab4d33022e7.jpg?hash=iKLowRabrU)
Front Baffle is double 25 mm HDMMR (HDF) total 50 mm thick, Glued with each other & clamped.
![02 Glue.jpeg 02 Glue.jpeg](https://www.hifivision.com/data/attachments/48/48973-de2fb71245f99341639cd8c3d1bacfe4.jpg?hash=3i-3EkX5k0)
![03 Clamp.jpeg 03 Clamp.jpeg](https://www.hifivision.com/data/attachments/48/48974-132a3d594a0195b1786a0ef94e887389.jpg?hash=Eyo9WUoBlb)
Getting the Frame ready, Sides Top & Bottom. These are screwed with each other,
![04 Frame TBS.jpeg 04 Frame TBS.jpeg](https://www.hifivision.com/data/attachments/48/48975-cf15dc5566537909f76553faf8daaac5.jpg?hash=zxXcVWZTeQ)
Front face of Mids & Highs Enclosure
![05 Mids & Highs Front.jpeg 05 Mids & Highs Front.jpeg](https://www.hifivision.com/data/attachments/48/48976-7902a3faf7abb865b5105ca7c92ee1c1.jpg?hash=eQKj-veruG)
Assembly of Bracing in Bass Enclosure
![06 Bracing.jpeg 06 Bracing.jpeg](https://www.hifivision.com/data/attachments/48/48977-ae21766b36390a93be54fad9f5ea7383.jpg?hash=riF2azY5Cp)
Felt used for lining internal walls of Bass Enclosure
![07 Felt.jpeg 07 Felt.jpeg](https://www.hifivision.com/data/attachments/48/48978-45581803454ea94590b51317d399c3c2.jpg?hash=RVgYA0VOqU)
Gluing of Felt with internal walls with fevicol (Marine). I forgot to mention the glue I am using is Fevicol Marine grade
![08 Felt Glue.jpeg 08 Felt Glue.jpeg](https://www.hifivision.com/data/attachments/48/48979-6dea1578fd0c38fb9433e07ac6e51365.jpg?hash=beoVeP0MOP)
Mid Enclosure assembly
![09 Mid Encl 2.jpeg 09 Mid Encl 2.jpeg](https://www.hifivision.com/data/attachments/48/48980-80159a9845269bd0450b2f1ebae42c6b.jpg?hash=gBWamEUmm9)
![09 Mid enclosure Assembly.jpeg 09 Mid enclosure Assembly.jpeg](https://www.hifivision.com/data/attachments/48/48981-c56e6980265fd18ebc4d5ea9b6dc5cb8.jpg?hash=xW5pgCZf0Y)
Vents Cutting & Gluing. I am using Finolex schedule 40, A 4" Pipe for vents. It is very thick and very strong. This Pipe diameter is big for my Miter Saw so i have to make 2 passes to cut the pipe throughout.
![10 vent cutting.jpeg 10 vent cutting.jpeg](https://www.hifivision.com/data/attachments/48/48982-88a5dbfefa1fad6197480481a87d8684.jpg?hash=iKXb_vofrW)
![11 Vent Glue.jpeg 11 Vent Glue.jpeg](https://www.hifivision.com/data/attachments/48/48983-4e994a676caf452223c8e636111b8f93.jpg?hash=TplKZ2yvRS)
And here is my new toy again "Makita RP2301FC" Router to make the Round-over on the Vents. Its a very Powerful Router with 3.25 HP of Power. The coll-et size is 12 mm. It has variable speed so I can control the speed, this feature is very useful while using big diameter bits. This Router is Beast, I didn't feel any load on this machine, it was running like a hot knife on Butter. It is also very heavy but when using it, it was very steady and very comfortable. The Plunge mechanism was the Best among the routers which i have used till date.
![12 Vent Radius.jpeg 12 Vent Radius.jpeg](https://www.hifivision.com/data/attachments/48/48984-27489258e7bc874b39f1b866bcbf4ec6.jpg?hash=J0iSWOe8h0)
The Radius of round-over is 19 mm. It just took 2 passes to get the job done. It is very difficult to do this radius with lower power rated routers.
![13 Vent Radius.jpeg 13 Vent Radius.jpeg](https://www.hifivision.com/data/attachments/48/48985-b69a7badd75ff7ce48856babf6fb40b0.jpg?hash=tpp7rddf98)
Assembly of Front Baffle, In Front Baffle I have not used screws, Its just glued, However the Back Panel is screwed with Sides Top & Bottom.
![14 Assembly of Top & Bottom.jpeg 14 Assembly of Top & Bottom.jpeg](https://www.hifivision.com/data/attachments/48/48986-afd8158d1acea90d55aa40fbb1f2ffe7.jpg?hash=r9gVjRrOqQ)
After gluing today I did sanding, The HDMMR sheet is very hard I had to use belt sander to sand the edges and then Orbital sander for smooth finish, After sanding I patched the holes of screws with sawdust and glue.
![14 Sanding with Belt Sander.jpeg 14 Sanding with Belt Sander.jpeg](https://www.hifivision.com/data/attachments/48/48987-2d80d2866e316d9c738d0e919c581e65.jpg?hash=LYDShm4xbZ)
![15 Filling up the Screw Holes.jpeg 15 Filling up the Screw Holes.jpeg](https://www.hifivision.com/data/attachments/48/48988-991dff5ea36d121173efe5f48dfa0f59.jpg?hash=mR3_XqNtEh)
This is the built journey till today. I will update this thread as i progress further.