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Grant .


Joined: 11 Aug 2009 Posts: 1148 Location: Los Angeles
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Posted: Sat Jun 03, 2017 6:13 pm Post subject: Building a lightweight 1x12 cab |
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I am fundamentally incapable of not overcomplicating everything.
color key:
sand: cheap pine ply
tan dowels: poplar
tan veneers: super cheap Home Depot 1/8" generic hardwood ply. inner veneers not pictured
pink: extruded polystyrene insulation foam sheet (Foamular)
speaker (neodymium): Jensen Jet Tornado 80
It's more or less assembled at this point, pictures to come.
todo:
- make speaker and back baffles
- apply wood filler to unwanted gaps/holes
- rout roundovers (1/2")
- paint
- mount speaker, baffles, handle, corners _________________
Last edited by Grant on Sun Jun 04, 2017 11:03 am; edited 8 times in total |
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Grant .


Joined: 11 Aug 2009 Posts: 1148 Location: Los Angeles
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Posted: Sun Jun 04, 2017 5:01 am Post subject: |
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Make them walls:
Layer 1/2" ply together, CNC out the middle:
Cut foam from 2'x2'x1" sheets, also with CNC:
Combine?:
As with the top:
As with the not-at-all-ambiguously-marked bottom:
Add
Done.
Wait 24 hours for adhesive to cure. _________________
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Grant .


Joined: 11 Aug 2009 Posts: 1148 Location: Los Angeles
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Posted: Sun Jun 04, 2017 5:12 am Post subject: |
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Continue them walls:
Plane sandwich parts to final thickness:
Forget to take pics of anything but the sides.
TEST FIT THEM MOTHERFUCKERS:
Note the dovetails. The dovetails were a mistake. More on that later. _________________
Last edited by Grant on Sun Jun 04, 2017 5:28 am; edited 1 time in total |
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Grant .


Joined: 11 Aug 2009 Posts: 1148 Location: Los Angeles
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Posted: Sun Jun 04, 2017 5:13 am Post subject: |
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Summon a skeleton:
hail satan. _________________
Last edited by Grant on Sun Jun 04, 2017 5:42 am; edited 1 time in total |
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Grant .


Joined: 11 Aug 2009 Posts: 1148 Location: Los Angeles
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Posted: Sun Jun 04, 2017 5:18 am Post subject: |
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Neglect to take pics when gluing the veneers.
Test fit like there's no tomorrow:
Give blood sacrifice:
HAIL SATAN _________________
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Grant .


Joined: 11 Aug 2009 Posts: 1148 Location: Los Angeles
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Posted: Sun Jun 04, 2017 5:27 am Post subject: |
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On dovetails in plywood, and why they were a bad idea.
The dovetails were added to the design when I still planned to use solid wood. When I made the switch to plywood, I did not reassess their inclusion.
I assume there are ways to do this correctly. I'm just learning CNC stuff, and doing so with dulled communal endmills. I ended up with lots of tear out:
This was compounded by the fact that I left entirely too much to hand-finishing. I didn't take full advantage of the CNC's capabilities, didn't design with them in mind, so I ended up sloppily bashing/sanding/cutting things to fit. So it goes! _________________
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Grant .


Joined: 11 Aug 2009 Posts: 1148 Location: Los Angeles
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Posted: Sun Jun 04, 2017 5:39 am Post subject: |
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Pre glue:
Design flaws and inexpert hand-finishing left gaps, and wood glue is a very poor gap filler, so I opted to use polyurethane construction adhesive. Polyurethane construction adhesive expands when it cures, moreso than I anticipated. I don't have any pics of the post-cure state of the cab, but a mm or two have been added to the width and height due to the expansion between the walls and the skeleton. S'all good. Should be easy to avoid next time. _________________
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Fakir Mustache .


Joined: 25 Sep 2013 Posts: 3145
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Posted: Sun Jun 04, 2017 7:20 am Post subject: |
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Wow, that's a lot more complicated than most manufactured cabs. _________________
dezb1 wrote: |
I only buy synths with mini keys as I like the shortscale synths. |
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paul_ .


Joined: 27 Jul 2006 Posts: 8879
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Posted: Mon Jun 05, 2017 6:02 am Post subject: |
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So fucking cool _________________
Aug wrote: |
which one of you bastards sent me an ebay question asking if you can get teh kurdtz with that 64 mustang?  |
robertOG wrote: |
fran & paul are some of the original gangstas of the JS days when you'd have to say "phuck" |
Fran wrote: |
Chamone motherfucker. |
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Grant .


Joined: 11 Aug 2009 Posts: 1148 Location: Los Angeles
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Posted: Sat Jul 22, 2017 6:56 am Post subject: |
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Progress!
Routed all outer edges with a 1/2" roundover bit:
Ridiculous tear-out of the cheap plywood veneer:
Short recap: design flaws resulted in joints that wouldn't work with wood glue. I chose to use polyurethane construction adhesive for its gap-filling properties. Turns out it's easy to overdo the glue when you don't know what you're doing, and that gap-filling glues can expand gaps.
Gap at corners:
Gap between wall, veneer.
Welp!
I set about closing inner gaps with caulk and outer gaps with wood filler. I had never used caulk before, and decided to skip the "tape what you don't want caulked" step.
Results were predictable:
Looks like someone murdered the Stay Puft Marshmallow Man.
Wood filler on the corners/etc. Bondo would have been a better choice, I think.
Looking good. Looking real good. _________________
Last edited by Grant on Sat Jul 22, 2017 7:02 am; edited 1 time in total |
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Grant .


Joined: 11 Aug 2009 Posts: 1148 Location: Los Angeles
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Posted: Sat Jul 22, 2017 7:00 am Post subject: |
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Things are ugly. Let's try to make them less ugly, a little, maybe.
Go back over the edges with the roundover bit:
Pause for selfie with the nerdpace's mantra:
Spend untold hours sanding, scraping, chiseling, etc.:
Hail Satan. _________________
Last edited by Grant on Sat Jul 22, 2017 7:22 am; edited 1 time in total |
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Grant .


Joined: 11 Aug 2009 Posts: 1148 Location: Los Angeles
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Posted: Sat Jul 22, 2017 7:14 am Post subject: |
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That looks way better than it should. Onward!
Speaker baffle:
Wood filler.
Back baffle:
Wood filler.
Handle:
Note that the screw holes don't line up. I had used the measurements of another handle, apparently. Welp.
Next update: painting. God help us. _________________
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Grant .


Joined: 11 Aug 2009 Posts: 1148 Location: Los Angeles
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Posted: Tue Aug 01, 2017 11:14 pm Post subject: |
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With regards to the handle:
This is the thing I designed/cut/drilled for:
This is the thing I bought:
I've used the opportunity to start learning Fusion. I intend to print it at the local nerdspace.
 _________________
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Doog can i get uhhh

Joined: 24 Apr 2006 Posts: 19104 Location: London
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Posted: Wed Aug 02, 2017 10:02 am Post subject: |
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Amazing! |
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