My 5-Way DIY Speakers Are Almost Done

[azzd]

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.

7737577376

[1audiohack]

Hi azzd!

Properly integrated those are going to be AWESOME!!!

Please keep us up on how you go.

All the best,
Barry.

[hjames]

Looks very intriguing!!
Roughly where in Virginia are you (I'm in Fairfax)
- maybe you'd consider a listening party at some point??



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.

[srm51555]

Nice work!

[azzd]

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:D

[azzd]

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.

[azzd]

Nice work!

Thank you srm51555!

[azzd]

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

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[azzd]

Got the plywood boards. Estimated what they might look like and prepared the top and bottom pieces.77392773937739477395

[azzd]

Cut the front panels. Due to the weak router and my poor skill, it took three days (may be coldest three days last winter:banghead: ) to get them done.7739977400

[Mitchco]

Really nice build! Glad you used Acourate. Did you time align and linearize the drivers as well?

I bet they sound great!

[azzd]

Finally they looked like speaker cabinets, while living room was really messed.774017740277403

[azzd]

Bracing, bracing, internal cabinet for Gauss 3184A, and more bracings.7740477405774067740777408

[azzd]

Installed the horns, seal tape, applied the Absorption coating in the cabinets and on the drivers, and the finished back panel7740977410774117741277413

[azzd]

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.

[Mitchco]

azzd, time alignment is hard to get it right down to a sample either way. I think you will find your IACC will increase with time alignment. For sure, a 5 way is a daunting task, but it should pay off. I agree with Rod's assessment of time aligning drivers: http://sound.whsites.net/ptd.htm

I have to tell you it took me three tries to get it in the ballpark of understanding what was going on. My book in the sig has a much more detailed step by step than he article you read. However, I am happy to assist if you want to PM me, when you are ready. Really nice speakers, would be a shame not to have the drivers timing nicely integrated, especially since you already have the digital XO.

[Doctor_Electron]

As in I love the way you are utilizing "Living Space". Three cheers, hip hip...:applaud:

[hjames]

But ...
but ...
its all about the SOUND!




As in I love the way you are utilizing "Living Space". Three cheers, hip hip...:applaud:

[azzd]

Mitchco, THANKS AGAIN! Do you mean this book (https://www.amazon.com/dp/B01FURPS40)? Please let me know. I am going to buy it and study some basic concepts. Will definitely ask your help whenever I couldn't go through:D

[azzd]

As in I love the way you are utilizing "Living Space". Three cheers, hip hip...:applaud:

The space is cleaner and net now:p

[Mitchco]

Mitchco, THANKS AGAIN! Do you mean this book (https://www.amazon.com/dp/B01FURPS40 )? Please let me know. I am going to buy it and study some basic concepts. Will definitely ask your help whenever I couldn't go through:D

Yes. Have fun!

[Dr.db]

That is a very nice collection of speakers in an impressive enclosure!

Would you share your final crossover points and slopes of your setup?
Why did you choose that tweeter over a JBL 2405 for example?

Have you considered to put your cabinets on some speaker-stands?
Raising them a little of the ground would prevent the 2235h from sounding boomy...

[bldozier]

why was the horn not mounted internally inside the cabinet did you not make the back
baffle removable.

those looks awesome, small for their space but very domineering. nice work.

[azzd]

Thank you Dr.db. Sorry for the late reply. Have not got chance to check the forum recently. Got Mitchco's book for months, no time to do further measurement yet.

The crossover points are: 193, 915, 3200, and 10000. Linear 2nd order Neville-Thiele. I am not experienced. Setting the points based on what Westlake does and the drivers measuring result.

Since I couldn't find good price 2406 as Westlake uses. There was a good deal of the RAAL last year; and I found they may go higher frequency. So, tried the ribbon tweeters; and there is no special reason:D

They are too heavy to put on stands for me right now. Thanks for the great idea! I may add the stands in the future.

Bests,

azzd


That is a very nice collection of speakers in an impressive enclosure!

Would you share your final crossover points and slopes of your setup?
Why did you choose that tweeter over a JBL 2405 for example?

Have you considered to put your cabinets on some speaker-stands?
Raising them a little of the ground would prevent the 2235h from sounding boomy...

[azzd]

Thank you bldozier!

Mounting on the front baffle is the only way I know:banghead: This is not good if 2450 and 2425 drivers having problem. The back baffle is removable, but those many screws will be a big pain. I will make only the upper part removable want need to open it.



why was the horn not mounted internally inside the cabinet did you not make the back
baffle removable.

those looks awesome, small for their space but very domineering. nice work.