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Thread: Ian's (& Bo's) 4345 project

  1. #1
    Senior Member Ian Mackenzie's Avatar
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    Ian's (& Bo's) 4345 project

    I thought is appropriate to start a new thread to illustrate and document the progress on building this monitor, or more correctly adapting my existing JBL boxes to the 4345 spec.

    As the title of the thread suggests, Bo the damm Yankee from parts unknown is the catalyst for the idea, having published the dimensions in the 4345 plans thread elsewhere.

    So where am I up to? Don't ask me, not exactly sure, but my back aches and I need an assistant.

    O'kay here are some of the tasks: The 39 Steps

    1. Sketch & sign off drawings for baffle cut-outs (done)
    2. Purchase Jasper Jig and 1/4 in router bit (done)
    3. Purchase 18mm Mdf materials (done)
    4. Plan sequence of baffle fabrication and overall project
    assembly (done)
    Make jig frame for holding baffles (done)
    Cut baffle circles (top layer then bottom layer - done)
    Drill driver mounting holes (done)
    Cut 18 mm MDF for Dog boxes (done)
    Screw & glue dog boxes to 2nd MDF layer (done)
    Laminate top and bottom MDF layer with PVA glue using a
    dozen or house bricks for a press (done 1 baffle)
    Clean, trim and sand & apply undercoat to finished baffles

    5. Amend height of existing cabinet & volume by 6 inches (done)
    6. Cut out existing baffles & make rear access opening
    Drill screw holes for baffle mounting
    Re paint cabinets with 2 pack Dulux effects paint finish (Arab
    Sand effects paint)
    7. Clean & vacum cabinets and fit new 3/4 inch fibre glass fill

    8. Wire and fit crossover
    Purchase 6 new x 100 watt faders (done)
    Purchase Holvand capacitors for all horn filters (done ouch)
    Assemble crossovers
    Wire and calibrate faders with std JBL test jig
    Fit crossovers in sealed sub enclosures

    9. Fit new baffles, glue and scew
    10. Fill screw holes, clean and paint baffles
    11. Fit drivers

    12. Check for air leaks & vibrations using low frequency sine
    wave tones via Phase Linear 700.
    13 Test, measure and evaluate new boxes (pray)

    The list is my no means complete, with special jigs and processes being thought out as each step is taken.

    Obviously this is not a weekend project, I'm down to task 5 or thereabouts, and there are plenty of new and sometimes daring challenges along the way. Photos are being taken as the project creeps forward.

    So far touch wood, there have been no major issues, although cutting the top of the existing boxes was a painful, in more ways than one... Muhahahahahaha

    The stouter boxes are more waf friendly I have to report and perfect elbow height for a beer tasting says I.

    More news shortly...here is an early version of the baffle drawing:

    Ian

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    Last edited by Ian Mackenzie; 10-13-2003 at 05:12 AM.

  2. #2
    Senior Member Ian Mackenzie's Avatar
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    The earlier cabinets:

    Ian
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  3. #3
    Senior Member Ian Mackenzie's Avatar
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    The 4345 cabinets we are now so familar with:

    Ian
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    Last edited by Ian Mackenzie; 10-13-2003 at 05:27 AM.

  4. #4
    Senior Señor boputnam's Avatar
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    Man, you are goofy to attribute any credit in this to me! You're the 4345 Clone Slave - not me! I'm mighty glad to be able to help-out with a few measly measurements. But even in that, it took me an extra week to get a dang metric tape!

    I can tell you, there's been more than once I wanted to remove all them transducers and get some real answers for you. If you'd have come across, we coulda done just that, over a few bottles of Shiraz Blend... Your plan looks real good - and I now the actual one is precise.

    Here's what's on my list:

    1) Get home during the day to drag the 4301B's to the paint store and model that JBL Blue for your baffles.

    I think we'd all be interested in what the total materials cost, is pard', when you're done. Might help relieve some eBay hubris, and get people to buy the cabinets they long for! IMHO...

    Keep your ear muffs on, hey?
    bo

    "Indeed, not!!"

  5. #5
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    "Get home during the day to drag the 4301B's to the paint store and model that JBL Blue for your baffles."

    'bout time!

    I need twenty or thirty gallons of the stuff to paint my house with

  6. #6
    Senior Member Ian Mackenzie's Avatar
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    Cheers Bo,

    "I can tell you, there's been more than once I wanted to remove all them transducers and get some real answers for you. If you'd have come across, we coulda done just that, over a few bottles of Shiraz Blend... Your plan looks real good - and I now the actual one is precise."

    Don't worry there will a few bottles of red drunk when this job is done.. and when I rock over your way a few more....muhahaha.

    As for materials to construct the baffles and make alterations its run up to AUS $150.00 incl safety goggles. Setup cost for Jigs and router bits etc about AUS $140.00.

    I esimate the cost of the crossovers (using Hovlands, AEON & 100 watt faders) is about $400 in parts, the drivers, well we can all guess that one...muhahahahah

    To make the boxes with 1 inch MBF for the cabinet walls is about $30 a metre here so I would guess 6 metres or another $180. Plus 10 metres of F17 hardwood for bracing., scews glue etc, sweezers for splinters etc about $50.00

    The means or tools of trade which are precison like the (USA) Jet Table Saw and Porter Cable Router are another matter. Plus the experience on hand from one who knows is hard to come by.

    My previous two attempts on the baffle color have failed, thougth I was in the Greek Islands with the last effort. Whats is the colour called ..JBL blue

    Ian
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    Last edited by Ian Mackenzie; 10-13-2003 at 12:39 PM.

  7. #7
    Senior Member Ian Mackenzie's Avatar
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    A short update.

    Nearly completed the both the baffles today.

    Just need to fix the hardwood frame edging around the baffle and taper with the router.

    Its looks very good and no mishaps thus far (touch wood)
    Taken 18 photos (sorry only normal Nikon) and will arrange work in progress photos in a day or two.

    Querry: The little plastic adjustment (tweekers) on the JBL level pads. Does anyone know the JBL part number or have any spare they don't need??

    regards

    Ian

  8. #8
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    "Querry: The little plastic adjustment (tweekers) on the JBL level pads. Does anyone know the JBL part number or have any spare they don't need??"

    52192

    From the latest Pro miscellaneous parts list -

    52192 - KNOB BLK DPTTED *52191 $2.40 USD EA

  9. #9
    Senior Señor boputnam's Avatar
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    Originally posted by Ian Mackenzie
    Just need to fix the hardwood frame edging around the baffle and taper with the router.
    That is something Widget and I worked on to get close-as-possible to original. I don't know if you're trying to do the same, but if so, here a crude image I worked=up in Paint for Widget (he's yet to come down to collect his own measurements... ).

    And, er, uh, it's Imperial.
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    bo

    "Indeed, not!!"

  10. #10
    Senior Member Ian Mackenzie's Avatar
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    Thankyou (both),

    Like the drawing Bo,

    This is the sort the thing I am looking at, it will be very similar if not identical..

    Here's an interesting statistic from the project: 6 buckets of saw dust.


    Ian

  11. #11
    Senior Member Ian Mackenzie's Avatar
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    Cut out around the old baffles yesterday,

    Two inches of mdf was a bit of an ask the the junior power saw. Will have to hand saw through the remaining hard wood bracing which is over 4 inches deep from the surface on some areas.

    Will post some pics shortly.

    Ian

  12. #12
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    Originally posted by Ian Mackenzie
    Just need to fix the hardwood frame edging around the baffle and taper with the router.
    Have you considered abandoning recessed baffles and going with flush, rounded baffle edges such as used on the 240Ti or 250Ti?

  13. #13
    Senior Member Ian Mackenzie's Avatar
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    Yep,

    I know the implications, l'm just following tradtion at the moment.


    Its only a 10 mm recess in this insance and I intend to make some grill cover later( but can always plane down the recess)

    Ian

  14. #14
    Senior Member Ian Mackenzie's Avatar
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    Here is a series of photos ..work in progress.

    The first shot shows the Porter Cable router with Jasper jig attached, and the baffles mounted in a Frame Jig ensuring alignment of the centre holes.

    The Frame jig was made of spare particle board and enabled precison and consistency during the complete circle cutting and laminating process. (Dad's idea...what are dads for.....)

    Ian
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    Last edited by Ian Mackenzie; 10-27-2003 at 01:47 AM.

  15. #15
    Senior Member Ian Mackenzie's Avatar
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    Next, nearing completion of the first of four baffle cuts and still gaining experience with the Jasper Circle Jig.

    Ian
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