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Last of the GR Research builds - 5.1 kit

Wharfedale Evo 4.2

captrajesh

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Many of the senior folks would remember that a group of our forum members had got together and got loudspeaker kits imported from a US based kit supplying company GR Research. The entire saga of the import process was documented in this epic thread.

While participating members were free to choose any of the kits, a majority of us had chosen the X-Series kits, specifically the X-LS Classic / X-LS Encore kits, because of the stupendous VFM factor.

I went in for a 5.1 set up. So, in addition to the X-SLS Encore (Floor stander version using the X-LS kit) for the mains, I've gone in for X-CS Encore for the centre (not listed on the site), the A/V 1RS for the rear surrounds and the 12" Servo Controlled subwoofer driver to be driven by Rhythmik Direct Servo Sub woofer Amp A370PEQ in a sand filled sub woofer enclosure.

Several members have documented their builds, links to which could be assessed by clicking on my signature. I'm probably the last to take up the build because I was already having a good stereo rig and there was no place to keep the 5.1 setup in the smallish apartment that I was living then at Chennai.

When I got relocated to Trivandrum on transfer last year , I took a reasonably big house on purpose because I wanted to build the HT setup after all. I could locate a professional team of two brothers who make speaker boxes for theatres who also happened to be one of the interior work contractors of the organisation that I am working for.

We've started the work in all earnest sometime in January this year. However because of their professional commitments and my office hours, we could work only on one or two weekends every month.

I was clicking the pictures religiously during the build process but initial procrastination on my part and the tediousness of uploading the pictures later as the pictures got piled up have forced me to postpone documenting the build process as and when it happened.

Now that the build has come to close and I have a few queries to seek answers to, I've decided to start the thread and think of posting the pictures later, in due course.

To be continued...
 
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captrajesh

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The Band of Brothers in their old workshop where the build is progressing. They complement each other perfectly. The one on the left is the elder one Mr. Gopa Kumar who handles the logistics and administration and the one on right is Santhosh, who does the actual work.




To be continued...
 

captrajesh

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Appearances can be deceptive. They make boxes for threatres throughout Kerala and Southern Tamil Nadu. In fact they have made speakers for theatres as far as Southern Andhra Pradesh. Santhosh has so much experience and knowledge that he can be an acoustic consultant. :)

The first cut:


Cutting in progress:


Making of Front Towers in progress:






To be continued...
 
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captrajesh

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captrajesh

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Affixing the braces:






Cutting Driver holes (Tweeter)




Cutting Driver holes (Woofer)


Baffle fixed


Baffle upclose


Chamfering of woofer hole


Checking driver holes fit



Hole for sandfilling of bottom compartment


Making the sandfilling hole




Nylon plug fabricated for fixing on the sandfilling hole




Affixing the bitumen sheet on the cabinet walls


To be continued...
 
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sadik

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Very Well Built :clapping::thumbsup:... Please don't compromise during finishing stage... In the End it matters on looks too.... U going good so far... Carry on the good work :thumbsup:
 

captrajesh

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Thank you Sadik.

The Centre Speaker X-CS Encore



The Surround Speaker A/V 1RS
Checking the angle


Chiselling off the excess MDF.
This process is suitable for creating MDF panels with slight angles


Result of chiselling


Planing to get the panel with correct angle.


Making the surround.




Result of deep angle cut
 
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keith_correa

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venki7744

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I am in the process of making a straight TL for my TV using some Peerless mid bass,now having seen the skills of these guys, I am having second thoughts on whether I should post the build thread :(. Rajesh sire, waiting for your message so that I can accompany you to watch rest of the build. For Beveling I am in the process of making a Jig based on router/planer machine. Will post details if I am successful :).
 

captrajesh

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I notice that he did not use any guide to get the cut as per the marking done on the MDF - I think he cut it more than needed. How did he finally get the edges to align perfectly before gluing up?
Be it straight cuts with jig saw or the straight/ angular cuts with the circular saw, he cuts 1mm more than what is required so that excess material to the tune of 1 mm is available on the panel. Since these cuts are not perfectly straight, he uses planer to shave off the excess material.

having seen the skills of these guys, I am having second thoughts on whether I should post the build thread :(.

Of course you should post the build thread. Why not!

Rajesh sire, waiting for your message so that I can accompany you to watch rest of the build.

They wanted me to come to their new workshop to finish off the Frugel Horns of Satyamoorthy on Tuesday but I couldn't spare time. Will try and fix up in a day or two.

For Beveling I am in the process of making a Jig based on router/planer machine. Will post details if I am successful.

Are you beveling the edges of speaker panels? Won't that reduce the surface area available for the glue?
 
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captrajesh

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Since these cuts are not perfectly straight, he uses planer to shave off the excess material.
Sorry, forgot to mention. He predominantly uses the router for straight cuts. Planer is used for angled cuts.

@Sathiamoorthy, yes, you must start a thread.

Here are the balance pics of the surround build:

The Baffle (This would be facing the ceiling)


Checking the fit of drivers


The rear side (Note the slot on the top portion of the depression for wall mounting)


The side view


The front view
 

venki7744

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Are you beveling the edges of speaker panels? Won't that reduce the surface area available for the glue?

No sire I want to bevel edges for two reasons:

* For corner bracing I need a strip with 45 deg cut on both sides. I can do this in my Juggad table saw but getting exact measurements is a pain (I will try this route first).
* While building a tapered TL box in the past, I had struggled to connect a piece of wood to another at an angle. I have not used Planer in the past and not a skilled or trained carpenter to try that as well. Whatever I do is due to the skills of my power tool :eek:hyeah:

IMO best option for bevel cutting at any angle would be using tilt router :).
 

keith_correa

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Be it straight cuts with jig saw or the straight/ angular cuts with the circular saw, he cuts 1mm more than what is required so that excess material to the tune of 1 mm is available on the panel. Since these cuts are not perfectly straight, he uses planer to shave off the excess material.
Wow! I wonder why they do it that way. If they use a guide I'm sure the cuts will all be perfect or near perfect with no need to manually shave off stuff.
 

captrajesh

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Wow! I wonder why they do it that way. If they use a guide I'm sure the cuts will all be perfect or near perfect with no need to manually shave off stuff.

I expected this question but wanted to cross the bridge when it comes. :)

The surface after sawing can never be as smooth as the one that is planed or routed and hence not only the adhesion would be suboptimal but even the fit may not be airtight. The bigger the saw, the rougher would be the surface area resulting from the cut. By sacrificing 1mm they achieve far superior adhesion with the glue and ensure airtight fit.
 
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