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Thread: My 5-Way DIY Speakers Are Almost Done

  1. #1
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    My 5-Way DIY Speakers Are Almost Done

    It is time to appreciate all helps and advices getting from this forum. Allen and Barry, I hope you will like the way I used the horns and drivers

    The project was planned last summer. I started to build the cabinets from Dec 10, 2016. The speaker size is 49.5 x 34.5 x 19 with components:
    JBL 2235H(x2)
    Gauss 3184a
    JBL 2450 with 2397 horn
    JBL 2425J with DIY horn
    RAAL 10-70D.

    The cabinets are made of 3/4” Baltic plywood. Front panel is doubled to 1.5".

    They are powered by Bryston 875HT and Boulder 500AE amplifiers via fully digital-crossing from Lynx Aurora 16. Originally, I used REW to do the measurement and design the crossover. Eventually I purchased Acourate to create the linear phase filters; and used the filters via JRiver.

    Since it is literally my first DIY project except one pair rough 2-way bookshelf speakers I built almost 20 years ago, the result is not bad. I believe what I learned may be a little valuable for beginners. Building the cabinets in winter without heating garage is painful. I had to do the gluing job in my living room, it took much longer than to dry. Jumping between the living room and garage made me impatient, which caused inaccurate cutting… Overall, low temperature makes almost everything difficult...

    Here are two pictures of the finished cabinets. I will make grilles to cover the uneven stained front panel. Will upload more building pictures.

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  2. #2
    Senior Member 1audiohack's Avatar
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    Hi azzd!

    Properly integrated those are going to be AWESOME!!!

    Please keep us up on how you go.

    All the best,
    Barry.
    If we knew what the hell we were doing, we wouldn't call it research would we.

  3. #3
    Heather [Senorita member] hjames's Avatar
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    Looks very intriguing!!
    Roughly where in Virginia are you (I'm in Fairfax)
    - maybe you'd consider a listening party at some point??


    Quote Originally Posted by azzd View Post
    It is time to appreciate all helps and advices getting from this forum. Allen and Barry, I hope you will like the way I used the horns and drivers

    The project was planned last summer. I started to build the cabinets from Dec 10, 2016. The speaker size is 49.5 x 34.5 x 19 with components:
    JBL 2235H(x2)
    Gauss 3184a
    JBL 2450 with 2397 horn
    JBL 2425J with DIY horn
    RAAL 10-70D.

    The cabinets are made of 3/4” Baltic plywood. Front panel is doubled to 1.5".

    They are powered by Bryston 875HT and Boulder 500AE amplifiers via fully digital-crossing from Lynx Aurora 16. Originally, I used REW to do the measurement and design the crossover. Eventually I purchased Acourate to create the linear phase filters; and used the filters via JRiver.

    Since it is literally my first DIY project except one pair rough 2-way bookshelf speakers I built almost 20 years ago, the result is not bad. I believe what I learned may be a little valuable for beginners. Building the cabinets in winter without heating garage is painful. I had to do the gluing job in my living room, it took much longer than to dry. Jumping between the living room and garage made me impatient, which caused inaccurate cutting… Overall, low temperature makes almost everything difficult...

    Here are two pictures of the finished cabinets. I will make grilles to cover the uneven stained front panel. Will upload more building pictures.
    2ch: RPi-4, Oppo, Acurus RL-11,Jolida 502,Valencias,JBL L212,Von Schw
    7: Oppo BDP103D, B&K, UREI 809A, JBL B460

  4. #4
    Senior Member srm51555's Avatar
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    Nice work!

  5. #5
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    Quote Originally Posted by 1audiohack View Post
    Hi azzd!

    Properly integrated those are going to be AWESOME!!!

    Please keep us up on how you go.

    All the best,
    Barry.
    Thank you Barry! I will post more pictures. Actually, I decided to do the five ways after talking with you about the 2425 driver

  6. #6
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    Quote Originally Posted by hjames View Post
    Looks very intriguing!!
    Roughly where in Virginia are you (I'm in Fairfax)
    - maybe you'd consider a listening party at some point??
    Thank you! I am live in Bristow, not far from Fairfax. Yes, why not? I hope get feedbacks and suggests from members here.

  7. #7
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    Quote Originally Posted by srm51555 View Post
    Nice work!
    Thank you srm51555!

  8. #8
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    Made the second pair horns for 2425s. Maple is really harder than I thought.

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  9. #9
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    Got the plywood boards. Estimated what they might look like and prepared the top and bottom pieces.Name:  IMG_20161217_185830.jpg
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  10. #10
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    Cut the front panels. Due to the weak router and my poor skill, it took three days (may be coldest three days last winter ) to get them done.Name:  IMG_20161223_162647.jpg
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  11. #11
    Member Mitchco's Avatar
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    Really nice build! Glad you used Acourate. Did you time align and linearize the drivers as well?

    I bet they sound great!

  12. #12
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    Finally they looked like speaker cabinets, while living room was really messed.Name:  IMG_20161226_174601.jpg
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  13. #13
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    Bracing, bracing, internal cabinet for Gauss 3184A, and more bracings.Name:  IMG_20170105_185459.jpg
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  14. #14
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    Installed the horns, seal tape, applied the Absorption coating in the cabinets and on the drivers, and the finished back panelName:  IMG_20170121_122443.jpg
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  15. #15
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    Quote Originally Posted by Mitchco View Post
    Really nice build! Glad you used Acourate. Did you time align and linearize the drivers as well?

    I bet they sound great!
    Thank you Mitchco! I read your post many times and followed the steps on your post to use Acourate. Do appreciate it! I tried to do the time align according to the measurement. Not sure whether I did it correctly, always got confused by the result. Eventually I gave it up temporally and used the distance to do the time align assumed there is no speed difference between Boulder and Bryston amplifiers (although I know there is). That's why I said the project is 'almost' done.

    I did drivers near-field measurement as you mentioned. They are pretty flat at near-field distance, but it's another story at the listening position. I could only get 70% IACC result.

    Acourate is really a great tool; and your post made things easier to a newbie like me.

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