Results 1 to 9 of 9

Thread: Broken corners on JBL crossovers? No problem!

  1. #1
    Senior Member Eric M.'s Avatar
    Join Date
    Jan 2015
    Location
    Oakland, CA, United States
    Posts
    135

    Broken corners on JBL crossovers? No problem!

    Well, not exactly. This was way too much work. It's probably easier to purchase a replacement crossover! Anyways, I wanted to see if it could be done.

    -Build up the broken corner with an aluminum welder. Tape off the rest of the faceplate. Aluminum welding splatters and will damage any aluminum the splatter lands on, especially the raised aluminum trim around the face of the crossover.
    -File the corner to proper size. Both corners, front and back. Build up with the welder if you have low spots and file again.
    -Coat the new corner with Bondo (automotive body filler) and sand smooth.
    -Put a faceplate with good corners over your repaired faceplate (Face to face), clamp together and drill out the holes on a drill press. This needs to be dead perfect. The holes, after countersinked, are very close to the edges. If you're off, when it comes time to countersink, you'll go right off the edge.
    -Countersink the new hole to match the existing.
    -Paint the repaired area.

    Sounds easy, huh? I had a handful of faces with broken corners, it was this or toss them out! This was more successful than the autoformers I tried to wind
    Attached Images Attached Images      

  2. #2
    Senior Member srm51555's Avatar
    Join Date
    May 2013
    Location
    Wisconsin
    Posts
    623
    Awesome work!

  3. #3
    Senior Member Eric M.'s Avatar
    Join Date
    Jan 2015
    Location
    Oakland, CA, United States
    Posts
    135
    Quote Originally Posted by srm51555 View Post
    Awesome work!
    Thanks!

  4. #4
    Senior Member 1audiohack's Avatar
    Join Date
    Jul 2007
    Location
    Las Vegas Nevada
    Posts
    3,092
    Wow that is real work! That die cast crap is not easy to weld.

    Good job there.
    Barry.
    If we knew what the hell we were doing, we wouldn't call it research would we.

  5. #5
    Administrator Mr. Widget's Avatar
    Join Date
    Apr 2003
    Location
    San Francisco
    Posts
    9,720
    Damn, you are a glutton for punishment!
    Impressive patience, perseverance, and skill... not necessarily in that order.

    Well, done.


    Widget

  6. #6
    Member
    Join Date
    Sep 2012
    Location
    West Virginia
    Posts
    56
    I am more impressed with the paint job, and how the lettering was left unpainted. How did you do that?

    Not that your welding work wasn't good (it is), but I have done lots of welding, so the paint job impresses me more.

  7. #7
    Senior Member BMWCCA's Avatar
    Join Date
    Feb 2006
    Location
    Virginia
    Posts
    7,743
    Quote Originally Posted by mmc8180 View Post
    I am more impressed with the paint job, and how the lettering was left unpainted. How did you do that?

    Not that your welding work wasn't good (it is), but I have done lots of welding, so the paint job impresses me more.
    Not welding. Bondo.
    Block sanding after paint give those results.
    ". . . as you have no doubt noticed, no one told the 4345 that it can't work correctly so it does anyway."—Greg Timbers

  8. #8
    Member
    Join Date
    Sep 2012
    Location
    West Virginia
    Posts
    56
    Quote Originally Posted by BMWCCA View Post
    Not welding. Bondo.
    Block sanding after paint give those results.

    Gotcha, of course. I'd say simple, but need a steady hand and light touch while block sanding. And the lettering must be high enough...

    Looks like both - welding then Bondo to smooth it out

  9. #9
    Senior Member BMWCCA's Avatar
    Join Date
    Feb 2006
    Location
    Virginia
    Posts
    7,743
    Quote Originally Posted by mmc8180 View Post
    Looks like both - welding then Bondo to smooth it out
    Yes, that is likely the hardest part, but that's the only way to make it strong enough. Nice work.
    ". . . as you have no doubt noticed, no one told the 4345 that it can't work correctly so it does anyway."—Greg Timbers

Thread Information

Users Browsing this Thread

There are currently 1 users browsing this thread. (0 members and 1 guests)

Similar Threads

  1. Broken Dome
    By Fort Knox in forum General Audio Discussion
    Replies: 7
    Last Post: 06-19-2013, 05:14 PM
  2. Broken JBL 6290 amp - what would you do?
    By gsb001 in forum Lansing Product Technical Help
    Replies: 9
    Last Post: 07-27-2010, 03:51 PM
  3. Help Needed-Broken 066
    By Oldmics in forum Lansing Product Technical Help
    Replies: 12
    Last Post: 11-29-2009, 03:26 PM
  4. Can anyone ID these JBL corners
    By ctrrap in forum Lansing Product General Information
    Replies: 8
    Last Post: 09-02-2007, 08:49 AM
  5. broken 2245
    By Thom in forum Lansing Product Technical Help
    Replies: 1
    Last Post: 08-20-2007, 10:50 AM

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •