Tapered Quarter Wave Tube (TQWT - mkII) Only Enclosure.

[sadik]

Hi Friends

From past 10 days, I have been doing this project in parallel with my other projects. I role is to only make the "finished enclosures" and then they will be shipped to the respected owner.

In past 10 Days I have completed the drawing, made cutting layout, and had the baffles cutting done on CNC router. And right now they are undergoing assembly.

I have used 24 mm Birch Ply for front and back and for rest of sides 18 mm Birch ply is used. The internal dimensions are matched as per the original enclosure made from MDF with has 30 mm Front & rest all sides 22 mm MDF.

Enough of right up, for details you can click on the below link for more details like Drivers and crossovers.
Tapered Quarter Wave Tube

Now I am sharing the photos of the work done till now.

All cutting is done on CNC router except for the 45 Deg joints. They are done with hand held circular saw.

When you have other project running in parallel you don't focus on taking photos, In the above photo of cut pieces, some are missing as the assembly was already started.


Checking the 45 Deg Cut Right angle which also has a provision to check 45 Deg Cuts.

When you have the perfect 45 Deg Cut, it reflects the same during assembly, see the matching of this joint in below photo.


Now sharing some random photos of assembly








Further i have to cut the degree of the tapered tube (baffle), for which i had used by router with degree attachment. It was as easy as (kaato-ghoolo aur lagao---- lol)






In below photo a brace is being glued & clamped with tapered baffle, Everything is glued no screws, it will be left overnight today for drying.




I will keep on updating this project also.

Sadik

 

[raghupb]

How many parallel projects @sadik Bhai?
Have you invented human cloning technology

Cheers,
Raghu

 

[shafic]

Excellent work as usual.
Bravo bro.

 

[sadik]

Further Update

 

[sadik]

Today's Update.

Today i finished cutting the through out hole for the tweeter fitment. Its very complicated to make such cutout.
First thing was, I had Jasper jig imported from US, but it is not suitable for routers which are available in India. Also at that time when i bought the jig, I did not had plunge attachment of my Makita Router. So I decided to make a custom Jasper Jig which can fit with my Makita router base (not the Plunge). Making a custom Jig, was not at all an easy task. You have to make the drawings and calculations for exact distance of each hole, Then you have to label them correctly....etc... etc. It was even hard to measure the exact centers of mounting holes of router base, (Not possible without precise measurement tools like vernier caliper) It is even more hard when you have to chamfer those holes, because after chamfering when the bolt is fitted it will itself make the hole center parallel with the threaded hole so if there is an error of 0.25 mm then you will not be able to fit the other screws as rest of the holes will be out of center.

Enough of write up now sharing the photos.
Here is the Jasper it is designed for 8 mm cutting bit. if you are using smaller bit then add the tolerance accordingly. This Router Jig is suitable for cutting circles of minimum 50 mm diameter to max of 400 mm diameter. This jig has a fraction of 1 mm increment for each hole. This jig is suitable for Bosch POF1400ACE & Makita RT0700C model routers.


Now sharing the Photos of the work.
A dummy wooden piece having same length as the internal is clamped with the help of F clamp. The right side panel is not glued right now, it is supporting dummy wooden piece to remain at its place. After clamping marking have been done as required and a pilot hole is made in which the pin will be fitted, then required hole on the jig will be selected which will be fitted in the pin to make the circle cut of required size. (refer below photos)




I have to make 105 mm Diameter hole. So after making a light cut I am checking the size with help of scale and yep its 0-0 (105 mm diameter)


Now ready to cut it throughout



The cutting bit was not long enough to cut it throughout, the small left over which is seen in below photo will be sanded off with circular sanding wheel.

 

[sadik]

Update:

In earlier post I had shared photo of my DIY circle jig. Today I made 2 new circle jigs which had additional fitment for plunge base of my Makita router. The Plunge Router is a must because, when you are flush mounting a driver you need multiple diameter cuts and each diameter cut will need the same depth which can be only achieved with help of Plunge. Because a plunge has a facility to lock the cutting depth. This is useful when you need the same depth in multiple wooden pieces. In our case we need same depth in multipe diameter cuts. Sharing photos my new revised Circle cutting Jigs.


In Below Image the Flush Diameter is 165 mm having a depth of 9 mm. The actual thickness of wave-guide is 8.5 mm, but i have made 0.5 mm more deep because after sanding and colouring this intentionally made error will get coverup. Secondly this jig has an error of 0.5mm, which can be corrected if I need. But in wood working 0.5mm error is negligible, its not a issue of too much concern.



In Below Photo I am cutting the actual cutout required for mounting the wave-guide.


Wave-guide fitted with the Front Baffle.


Checking the straightness of 2 holes to make sure our driver looks perfectly aligned






Actual test of my Jig will be tomorrow. This is how the wave-guide cutout is to be done & drivers to be fitted.


Sadik

 

[sadik]

Today's Update

Yesterday, I did required setup to cut the wave-guide as shown in my above post so today was the day to execute the plan. Unfortunately today the whole day there was no power, Being Sunday sometimes the Electricity guys cut off the power to do maintenance work. The power came back in evening 5:00 PM & I started my work. It took approx 2:30 hrs to cut the wave-guide & to cut the the speaker cutout as well as flush for both enclosures.

Lets have a look on today work


Closeup



In the above photo i have reached the max depth required for flush mount of driver. & in Below photo i have started to cut the actual cutout for driver fitment.

A step can be seen in above photo you may also notice that the wave-guide has now got its shape.


This is how the wave-guide look (above photo), I should have clicked this photo with different background, the same background is confusing as it gives a illusion as if the wave-guide is still attached to the Birch ply.

In below photo the speaker cutout is completed. The whole thing turned out to be pretty well & looks beautiful too.


I have also done a chamfer at the backside of driver to allow free rear ventilation. It can be seen in below photo

Tomorrow i will glue the sheep wool felt of 12 mm thickness as per design requirement and then glue the Side baffle of both enclosures & in last top panels will be glued. Right Now 1 Side panel of both enclosures and top panel is open.

 

[oldmonk]

Very beautiful !

 

[manniraj]

Awesome Sadik

 

[sadik]

Very beautiful !

Thank You

Awesome Sadik

Thankyou

Update:
Today I glued Sheep Wool Felt as per design requirement. I was lucky to get the sheep wool locally, but its little costly, I guess its costlier than acoustic foam, it was around Rs. 480/- per kg. The below quantity looks small but it weights good. The total weight of below Sheep Wool Felt is 3.2 Kg. The thickness is 12 mm




Its easy to cut it but you should have a very sharp knife

 

[oldmonk]

nice to follow Troels Gravesen as closely as possible to get the best results..

its a very interesting design..

do you know which amplifier will these be paired with ?

 

[sadik]

nice to follow Troels Gravesen as closely as possible to get the best results..

its a very interesting design..

do you know which amplifier will these be paired with ?

IT will be paired with USSA5 Mono-blocks, its class A amplifier

 

[oldmonk]

Thank you..

am very curious to know about sheep wool performance as compared to normal acoustic foam...

 

[sadik]

Thank you..

am very curious to know about sheep wool performance as compared to normal acoustic foam...

I wont be able to hear them as I am making only the enclosure part.

 

[adityavj]

This looks amazing! @sadik would you be able to make these for me ?

 

[sadik]

This looks amazing! @sadik would you be able to make these for me ?

Thank you @adityavj . You need same type of enclosure? We can have a conversation in PM.

 

[adityavj]

Thank you @adityavj . You need same type of enclosure? We can have a conversation in PM.

Sent you pm

 

[sadik]

Update:

Finished gluing the felt on required sides of the enclosure also glued the acoustilux (Polyester recron sheet) of 19 mm thickness as required behind the driver and at bottom of enclosure




Below are the spikes which will be attached with this enclosure


Tomorrow I will complete the same process of second enclosure.

 

[Beginner_N]

Why not use D Nuts instead of T nuts?

 

[sadik]

Why not use D Nuts instead of T nuts?

They came along with the set.