B460 Repair Project

[mbottz]

Here is a picture of my poor B460 when I got it. Some Dumb A$$ dropped it on its corner before I got it. This Thread shows how I am bringing it back to life to be used in my media room.

[mbottz]

This is where I use my router to cut the corner so I can replace the damaged portion of the corner. Make sure to use a strait edge to keep the work precise and neat.

[mbottz]

This shows the cut. The depth is the same thickness of a new piece fo MDF

[mbottz]

Next I relocate the straitedge and make another cut deeper than the first. I am stairstepping the repair for additional strength.

[mbottz]

Turn the cabinet on the other side and make a similar cut.

[mbottz]

With both sides of the corner routed to the correct depth and shape, Pieces of MDF are cut to size, glued and nailed into place. I use lots of wood glue, and finish nails to keep everything in place.

[mbottz]

Next the overlap is carefully sanded for shape with the belt sander. Then for the finishing shaping use Bondo to fill any imperfections.

[mbottz]

Here is the repaired cabinet after sanding and shaping. It may take several passes with the bondo and sanding to get it like you want it.

[mbottz]

A dab of Flat black so you can see any imperfections, and the corner is nice and square. At a minimum the right side, and top will get new venier. Most likely the complete cabinet will get a new skin. I have fixed many cabinets with this method and it works great. On regular cabinets such as L-100's you can re-venier 2 sides stain, and refinish to where it takes a close inspection to even tell there may have been a repair.

Part 2 may take a while as I work at a regular job that keeps me pretty busy. Please be patient and I will update this thread when I start the Venier work.

Any questions or comments are most welcome.

[mech986]

Excellent work! At first was hard to tell the orientation and which corner you were working on till I saw the ports. That corner is also more complicated because of the sloping front side panel that protrudes from the baffle.

Will be interesting to see the veneer work. Thanks for the instructive woodwork! :applaud:

[Valentin]

nice work congrats :applaud:

[mech986]

BTW, were those the ones from a San Antonio CL Ad? I remember seeing something like that. Pics below from the ad. If so, was there also a little damage to the front panel next to the grille too?

Did you ever complete your own DIY versions?

Edit: must be the same cabs, I can see the little front panel smush in your photo!

[mbottz]

That’s very interesting. That’s my B460. I picked it up about a year ago from the craigs list ad in San Antonio. Had the wrong woofer in it as well. Had a 2240 installed. Sounded good on preliminary testing. Have since purchased the 2245 for it. Just now getting around to putting it back into service.

The plan as of now is to build a mirror image of this one when finished using the DIY plans. Already have the new foilical, from RJ with a sequential serial number, as well as a sequential SN 2245 waiting in the wings. At the rate I am going though, it may be a while. Work keeps getting in the way.:(

Wow!! These pictures sure do get around.

mb

[mech986]

That’s very interesting. That’s my B460. I picked it up about a year ago from the craigs list ad in San Antonio. Had the wrong woofer in it as well. Had a 2240 installed. Sounded good on preliminary testing. Have since purchased the 2245 for it. Just now getting around to putting it back into service.

The plan as of now is to build a mirror image of this one when finished using the DIY plans. Already have the new foilical, from RJ with a sequential serial number, as well as a sequential SN 2245 waiting in the wings. At the rate I am going though, it may be a while. Work keeps getting in the way.:(

Wow!! These pictures sure do get around.

mb

Thanks for the confirmation. I archive any JBL related stuff for price trends and decent pictures. The pics above are from the original year old San Antonio CL ad, I even have the old text too. Were you able to get them for less than the asking price, especially with the damage and wrong woofer?

Good Luck on the mirror piece, Valentin's looks very nice. Wonder if anyone has created the CNC drawings for the mirror piece?

[John]

Were you able to get them for less than the asking price, especially with the damage and wrong woofer?

Interesting, what was the asking price?:blink:

[mbottz]

My memory is not what it use to be. I do remember I got it for around $200 to $250 less than the asking price. BTW what was the asking price in the AD?

MB

[mech986]

My memory is not what it use to be. I do remember I got it for around $200 to $250 less than the asking price. BTW what was the asking price in the AD?

MB

Here's the ad copy. I think the seller was a little optimistic about the original selling prices.


JBL B460 Home Subwoofer - $750

Date: 2008-03-29, 2:55PM CDT


This is the top of the line for JBL and retailed from $2100 to $3000. It is a 800 watt 18" die cast aluminum frame driver with an edge wound voice coil. You will not be disappointed. It reaches down to 16hz. Even underpowered it shakes the house. Cabinet has some corner damage as seen in pic and the grill clips need to be replaced.

[mbottz]

Well the week end was free and I had some time to get back to fixing the B460. The base was chipped up bad from all the moving around, so I had an idea to fix it that should help eliminate future chips and make it a bit easier to move on the carpet. I got out my laminate router and rounded the bottom corners.

[mbottz]

Next it was time to start the Venier lamination process. Out with the bondo to square up a few corners and smooth some surface imperfections. Then a heavy dose of contact cement on the subwoofer and venier. I left about 1/2 inch overlap all around. Then trimmed with my laminate router. Next I routed out the ports and a bit of finish sanding and one side is complete. I am using the laminate router because this venier is wood backed and is thicker than the paper backed type. This is my first experience with this type and so far it is working very well.

[mbottz]

The opposite side venier is is in good shape, all that was required was to remove and replace the edge band venier. This was acomplished with a hot iron and a sharp putty knife. The iron makes quick work removing old edge banded venier. I also use it to make sure the new venier is stuck down smooth and tight.

[mbottz]

Well here is something I was not ready for. To venier the front curved panel the wood backed type does not bend easily. So I had to build a special jig that would allow me to pre-bend the venier prior to applying. Once built I wet each area to be bent with a wet rag and used my hot iron to steam penetrate the water into the wood. When good and wet the venier was clamped to the form and allowed to dry. The form was made to bend the venier farther than needed so it would spring back into place and be very close. dont need the wood pulling itself off while drying. Adhesive was applied and behold the curved surface glued down without any issues. The venier was smoothed down with the hot iron and using the laminate router the edges were trimmed carefully and all sanded smooth to get ready for the next piece.

[mbottz]

After laminating the other sides and reworking the edge banding on the oposite side, here is the finished result. Ready to sand and stain. Stay tuned for the finishing. Hopefully work will allow me to finish it in the coming weeks.

[mech986]

Nice work!! Looking very good and I'm having a lot of fun following your progress. Thanks for sharing your work with us!! :applaud:

[Doc Mark]

Morning, MBottz,

Yes, very nice work, indeed!! Well done! :applaud::applaud: It's been fun watching you turn a sow's ear into what will become a silk purse!! :D:applaud: Thanks, very much, for sharing it with us, and I look forward to seeing how it all turns out, when you have time to get back to it. Time is the one thing that most of us need, and few of us have, unfortunately. Take care, and God Bless!

Every Good Wish,
Doc (Texas born)

[mbottz]

Well here are a few pictures of the finished product. From finish sanding, to a bit of stain for color, and Oil to round out the project I think it came out well. I installed this in place of my B380 and WOW what a difference!! this thing really shakes the house. If only I had two..:D

[MikeBrewster77]

Beautiful - excellent work! :applaud:

Congrats / Mike

[rdgrimes]

Wanna sell it? :bouncy:

[Doc Mark]

Hi, MBottz,

Super-duper, fantastic, and outstanding, Sir!!! Well done, Mate!! I would think that, after all the blood, sweat, and tears, such a fine subwoofer would not be for sale, but that's just me! ;) In any case, you did a wonderful job on that old, much maligned B460, and should be very roud of your work! Thanks, again, for sharing it with us, and enjoy that neat old JBL sub of your's: You've EARNED it!!! :applaud::applaud: Take care, and God Bless!

Every Good Wish,
Doc