Attempting a re-cone on my Sachenwerk field coil drivers

Hari Iyer

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Those who are following my post might be aware that I had a pair of Sachenwerk field coil drives from 1934 era and was using them since 2019. It lasted for 5 years and post that due to environmental dust and age the paper cone started to disintegrate slowly. This caused SQ issues and I had to dismantle them and install my Russian FR since past 2 years. I had last year attempted a recone with locally available materials off the shelf but they did not work well with the field coil and had to abandon the project.

Two weeks ago, I started to rethink about the recone and used AI for designing the driver material. I primarily used chatGPT and Grok to design and fed them my requirement. I also considered the ML-TQWT box where these field coil will go and also my living room dimension so that it will give a perfect recipe for the paper cone, surround, spider, whizzer cone, phase plugs, glue etc so that i can try to procure these materials as per my other design goals. It came out with a ribbed paper cone with foam surround with a mass of 8 to 10gms, a small 2.5" whizzer cone and 1.5" depth with an opening for phase plug, a medium-soft spider. This will allow a resonant frequency of around 45hz to 50Hz. The Qts of the driver will be tunable between 0.3 to 0.7 by varying the field coil motor strength. For my TQWT i will require a Qts of around 0.4 to 0.5. The total MMS should not exceed 12 gms which is a challenge. Below are the weight of my materials,
Paper cone - 10gms
whizzer cone - 1gm
Spider - 2 gm
Voice coil - 2 gm

This itself total to around 15gm. Add one gram of glue and the total MMS will be around 16gms minimum. There is an advantage of a slightly higher MMS as it help to reduce the resonating frequency. But this will also reduce the HF response of the driver and it will start to roll-off earlier. The whizzer cone will need to be carefully mounted on the voice coil edge to get maximum HF coupling and the phase plug wiil help in reducing phase cancellations. I ordered all the material from Bhopal and its scheduled to arrive this weekend. I have been reasonably successful in reconing large 12" woofer drivers which is more easy. Recone of the small field coil is a bit of a challenge as its a short gap and long length type. To prevent the voice coil grating require enormous skills as even a micrometer error will cause the grating of the VC against the pole piece causing enormous distortion. I am excited to start this project and keeping my fingers crossed about the outcome.

I had earlier this month thought of buying the SB Acoustics 8" FR driver as it was available at a reasonable cost, but both chatGPT and Gork suggested me to go with the field coil re-cone over the SB purchase for more organic, dynamic presentation of music from the field coil.

Thanks for looking.
 
Updates:
I re-coned my speaker on Friday evening and after adjusting the spider for micro grating of the VC on the pole piece this issue was resolved. But the spider is still not very compliant and is quite stiff. I have been doing a controlled break-in past 2 days but with limited success. Below the driver resonance of 50Hz the cone excrusion is quite high. This pushes the driver into non-linear zone causing LF compression and distortion. ChatGPT suggest 3 to 4 days of further controlled break-in with both music and sinewave sweeps at a suggested interval to reduce spider stiffness. Patience is the key here. FM @Satyaki Banerjee has recommended one+ month of controlled break-in. I will go by his suggestion and wait patiently for the spider to soften. The HF roll-off begins at around 8KHz and at 15KHz the response is -10dB down which is kind of ok for realistic listening levels. Good that the whizzer don't exhibit any shouty peak at around 2-3KHz. Shall update how it went as appropriate.

Thanks for looking.
 
After 10+ hrs of controlled break-in with suggested play and stop gaps by chatGPT at a very low level of around 1 watts the spider seems to behave and settle down. But it's still only 80% done. Volume increase to 15 watts and subjective low frequency is still restrained. The trick will be to patient for another 4 to 5 days and continue with the break-in process. I am now playing at 8 watts power without any issues at LF. The last 20% is going to take more time than the initial 80%. A crude SPL measurements from my mobile phone at 1khz sine wave @1 watt/ 1 meter was 97dB.
 
After an 48 hrs gap with break-in i today connected the first speaker to check. It now sounds normal with no LF compression or restraint. There is no rub,, scratch or grating of the VC against pole piece. I have now listened for 2+ hrs and did not find any issues at decent volume levels. I shall install this speaker in my vigot pipe this weekend.

In the meanwhile I also reconed the second speaker too. For this i used a humped spider and the VC centring was a bit offa challenge due to the soft spider. Its still in the settling stage and now it's under rest after the break-in past 6 hrs. There was no restraint initially with this due to soft spider, but this did have some serious LF compression. It took me 2 days of controlled break-in to reduce ( not eliminate) the compression. I have a small window of 6 hrs today evening to still recover this driver and shall start past 7 pm.

Thanks for looking.
 
I resumed controlled break-in again today afternoon after mounting my field coil in my ML-TQWT box. The spider is still very stiff and doesn't allow decent cone excrusion. The measured SPL is 87.5dB at 1watt, 1meter for pink noise. Also done a REW sweep and noticed the roll-off happening around 70hz and the F10 around 50Hz. Pulling the cone outward cause the suspension to snap back immediately indicating a stiff spider. Surprisingly the bass is very tight and deep enough.
 
Update: My cone + surround weighs around 11.5 gm. Adding VC, Spider, glue weight makes it around 15 gm. That is too heavy for my field coil to lift. The measured SPL is just 83dB. I was unable to source any paper cone that weighs around 5gm max.

I am planning to scrap one layer of paper from the existing 11.5gm paper and make it around 5gm to 6gm. It will be a fun exercise.
 
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