Re-building BS


Active Member
May 21, 2009
Kerala - Trivandrum/Kochi
Please help me in re-building my BS speakers which I will be using for 2 channel set up with Amp (mostly decided on Norge 1000)

Right now, I have the DIY BS (made by my friend around 3 years ago) and the specifications for the same are given below.

Design : 2-way
Drivers - 1x10" Bass woofer and 1x 3"x6" piezo horn tweeter.
Power Handling - 75 W
HxWxB - 60 cm x 38 cm x 35 cm.
Weight - ~20 Kg

The cabinet is made of good quality wood (dont know the exact name of the wood).

I am planning to replace the existing drivers, tweeter, and crossover for the new set up (as they started to distort nowadays). This will be used as Front speakers for my AVR in the future as well.

So, kindly let me know the specifications that I should look at for the new drivers, tweeters, and crossovers.
You are correct Cranky, itz not that easy to build it up. The main reason why I planned to re-build BS is the distortion that I am getting while driving the BS. The drivers are a bit old and hence it is causing the issue. I have found a few good 3x6 tweeter under Ahuja, but they basically make products for PA systems. Don't know how it will fare in home set up.

I do use a DIY Amp to drive it which is my current source.

I did check with Corrson couple of weeks back and they said they don't sell the items now except for some small-sized bookshelves.

In your opinion, what should be the crossover specifications for a 2-way 125W BS?

In another post you clarified what a 2.5 way design was. I quite liked the idea. With a slight variation. Is a 5" full range driver combined with a 6.5" or 8" low-mid driver in a crossover-less design workable for a BS? What shall I call it - a 1.5 way design?

cranky - can you conduct a speaker building workshop? For us in delhi/ noida?
It is not about saving money, it is about learning a complete new technology and art!

The Asawari |

@gobble: Yes, it would be a 1.5 way, but you'll need a low-pass crossover on the bottom driver to prevent lobing. The other issue you will have is floor bounce if the lower driver is too close to the floor, and if the baffle is too narrow you will have lobing near the crossover frequency anyway. So you need a sufficiently wide baffle to lower the baffle step frequency, and a pretty huge inductor (or better, an active XO). It could also be a combination of an OB + box for the lower driver, with the drivers sharing the baffle. What specific drivers do you have in mind? This is a pretty common concept for fullrange users AFAIK.

Thanks for the link.

I've realized I do not like the the treble float around distinctly and hence considering a fullrange driver to cover the mid-bass to upper frequencies.
However I also want lower freq extension to be better than a common full range down to 30hz if possible. I don't think a single full range driver can go so low esp with a BS size cabinet. So I am thinking with this kind of DIY design I could get some extra juice out of a BS size? I dont mind a BS 2.5" tall and 14' (inches) wide. The other thing I want is deep and rich tone even for the mids which the BS I currently have lacks. Again the enclosure size of BS may not really allow it, but I would like your comments on possibilities.

Can you also recommend the drivers to use for such a design? Please also correct my assumption if they are mistaken. I'm only going by common sense judgement not specialist knowledge.


edited: PS: As you know I have very sturdy logs of wood 2" height for stands, so distance from floor should not be the issue.
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Thanks for the info. I hoped it would help the original poster to some degree, but it is going more OT now. I will create a new thread on this in a few days.

My apologies for hijacking this thread.

I am an engineer and not a scientist. I need practical speaker building and not theory - so it is fine with whatever you teach us.
Designing a full range should be good enough to begin.
Or how to take measurements would be great.
Are the xonars, heavily recommended here good here for measurements?

actually, I came across aswaris last year and that made me get into exploring more. I wanted to do everything DIY but I realized I need to learn more with commercial gear.
@mmp: For a crossover to work we have to work with the specific drivers, which kind of depend on your room and tastes. We measure the impedance and response of the individual drivers and then design the crossover to produce a flat response through the entire range, but most importantly around the crossover region. Without knowing the response, it is impossible to tell what slope and topology to use.

I quite like the Peerless drivers that are available for DIY use. The 8" paper woofer can be gainfully used as a woofer or low-end driver, and their low-frequency tweeters could be used to come in early (they claim to work from 1KHz onwards) for a 2-way design, or one of their more conventional tweeters for a 3-way. I have not the tools, the time or the drivers available for such an exercise as of today (though, stay tuned...) but I've posted the story of a young designer called Tarun, who built an excellent pair of speakers from the ground up and documented it beautifully. Read about it to get a hint of the kind of effort you're looking at, and then tell me if the proposition is still interesting.

The Asawari |

thanks Cranky for the link provided. I have gone through it and now I understand that itz a very very cumbersome task :) However, the story inspires me and moreover I belive that the result of DIY will give me more satisfaction than getting a ready-made one from the Branded companies.

What I will do now is that put myself on search mode to find out better drivers and once I procure them I will contact you again so that we can discuss on it further. ( I belive in a week's time)
We need another thread for more questions, this may get too long a set of questions. Will you ask a mod to part out the thread please. I don't like a discussion that does not help the guy who asked the question.

Not a problem Cranky... anyway this is the place where we all come to share the knowledge and to tell you the fact everyday I am learning new new things from this forum. Itz really good to see that almost everyone answers each and every doubts or questions which are raised by people like me very emphatically.
I agree with Cranky. I've seen this happening with numerous threads that just meander along, some filled with nuggets of great information that is lost since the title is so far away from the content of the current posts.

Happened with Asit's "Canton Speakers" thread recently...lots of good informative posts in that one about various audio things....but lost in the noise now. I think we members should actively branch out a separate thread when we see it going astray. Are there tools available to the thread owner or participants to do this?
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