My 35 Year Dream
I bought the original KHORNS from my friend Tom. He built them in the late 70's, ordered the components from Speakerlab. I removed the woofers, tweeters, midrange and crossovers, scrapped the cabinets, I had to build them myself.
1/2" Marine Plywood-(5) full sheets, the only voids very small. I threw a 15" cutoff out into my yard - rained for four days. Not one sign of bubbling of delamination. Before I found the 1/2" Marine Plywood. I thought I would have to use metric (undersize) all the dimensions would be off. The marine plywood was a full 1/2" - Actually measured +.015 to +.020 more on that later. |
Some of the parts had to be stood up. "E" shown, I used a box with sandpaper attached. square up "E" and clamp to box.
"J" boards-cut a piece of 1/4" plywood at 22°. Adjust fence to compensate for blade. Layout lines on "J", set under 1/4" plywood, see scrap pcs to support 1/4" plywood. Line up layout line exactly with 1/4" plywood. I used Rockler #25736 Universal T-Track Kit. Remove 1/4" plywood and scrap pcs. Cut, index "J", cut other side. |
Layout of "A".
Use Plan drawing as a guide only. Most important are the center lines in both directions. Remember my plywood was oversize. If you use the 4-1/8" starting point, the "G" and "J" boards will not fit. Cut a 22" board, mark exact center line. Set on "A", line up with center line on "A", clamp. Now butt up "B" boards to 22" spacer. Glue/nail, remove 22" spacer board, set up for other end of "A". Mark "B" boards "B1/B2" first and set up for a dry run, you do not want to attach them in the wrong spots, Note the angle cuts on "B1/B2". Finish "A" assembly. I waited for glue to set up overnight, next morning flipped over screwed and caulked. I screwed everything on this project, close to (600) screws for both speakers. |
"H"- layout for 3 X 13 slot.
Rough out with jigsaw, stay away from line about 1/8".
Make jig shown. Double stick tape jig to layout line, press down hard to secure. Rout with bottom bearing router bit, shear angle carbide works good in plywood. After attaching "H" to "G", rout "G" with "H" being the jig.
Speakerlab plans show attaching "H" to "G" with machine screws, jam nuts, wing nuts. This makes no sense to me, you have to lift up woofer on "H" up and out. to install/remove.
I used 5/16" T-Nuts and hex bolts with washers. Socket wrench to install. I made small blocks (countersunk) to cover bottom of T-Nuts. Glued in place, they can not be knocked out.
Mark "H" and "G" with orientation symbols. Attack "Q" blocks around "H".
Rough out with jigsaw, stay away from line about 1/8".
Make jig shown. Double stick tape jig to layout line, press down hard to secure. Rout with bottom bearing router bit, shear angle carbide works good in plywood. After attaching "H" to "G", rout "G" with "H" being the jig.
Speakerlab plans show attaching "H" to "G" with machine screws, jam nuts, wing nuts. This makes no sense to me, you have to lift up woofer on "H" up and out. to install/remove.
I used 5/16" T-Nuts and hex bolts with washers. Socket wrench to install. I made small blocks (countersunk) to cover bottom of T-Nuts. Glued in place, they can not be knocked out.
Mark "H" and "G" with orientation symbols. Attack "Q" blocks around "H".
Stages of assembly.
This 9" long x 3/8 ID brass tube worked great for getting caulk into the deep areas hammer outside end to oval hold tight/tape on caulk tube nozzle.
Down and dirty flat black for now. I can very easily dress these up later.
I added garage door weather-strip to "P" boards to fit walls in the corners.
I added garage door weather-strip to "P" boards to fit walls in the corners.
Here they are, I made mine a right and a left, tweeters and doors on opposite sides.
My intention is to offer help to someone wanting to build a set.
If you have comments or questions, please call me.
Larry-(608)289-3475
I check my flip phone once a week, I will call you back.
Thanks for reading.
Larry
My intention is to offer help to someone wanting to build a set.
If you have comments or questions, please call me.
Larry-(608)289-3475
I check my flip phone once a week, I will call you back.
Thanks for reading.
Larry