Monday, May 18, 2015

Progress On The Corner Midrange Horn

The side wall flares will be connected to a pair of eight-inch long horns positioned in the corner between the walls.  Here are the six ribs in the process of being shaped with coarse sandpaper and block.  The clamp holds them in position so they will come out about the same size and shape.

Corner Midrange Horn - Shaping Six Ribs
Corner Midrange Horn - Shaping Six Ribs


Corner Midrange Horn - Shaping Six Ribs
Corner Midrange Horn - Shaping Six Ribs
 Here are two of the ribs in position in the a corner.
Corner Midrange Horn - Two Ribs In Position
 Here is one rib with the curved panel partly attached.  This shows the kerfs cut into the panel to make bending easier and more uniform.

Corner Midrange Horn - Curved Panel Attached
Corner Midrange Horn - Curved Panel Attached
 Now the curved panel is attached to both ribs with a side panel also in position.

Corner Midrange Horn - Partial Assembly Of One Horn
Corner Midrange Horn - Partial Assembly Of One Horn


Corner Midrange Horn - Partial Assembly Of One Horn
Corner Midrange Horn - Partial Assembly Of One Horn
 The first horn is assembled and the second horn will be put together after cutting a square hole in the "floor" for access to the throat.

Corner Midrange Horn - Second Horn Assembly With Throat Access
Corner Midrange Horn - Second Horn Assembly With Throat Access
Both horns are in position.

Corner Midrange Horn - Both Horns In Position
Corner Midrange Horn - Both Horns In Position
 Now, it is necessary to remove some wood from the center flare assembly ribs so they will fit into the space between the small horns now in position.

Corner Midrange Horn - Removing Wood From Ribs With Saw
Corner Midrange Horn - Removing Wood From Ribs With Saw
Corner Midrange Horn - Removing Wood From Ribs With Plane
Corner Midrange Horn - Removing Wood From Ribs With Plane

 Here is the center flare assembly in position.  More fitting is necessary to bring the joints in the side wall flares together for a closer fit.

Corner Midrange Horn - Center Flare Assembly In Position
Corner Midrange Horn - Center Flare Assembly In Position
 Here is a close-up of the throat of one of the horn assemblies.  You can see where the ribs are located and how they provide the proper curve for bending the panels.  Later on, a throat flange will be glued over the throat opening so a small two-inch speaker with back chamber can be mounted on each of the horn throats.


Corner Midrange Horn - Throat Of Horn Assembly
Corner Midrange Horn - Throat Of Horn Assembly
Here is a view of the other horn assembly throat.
Corner Midrange Horn - Throat Of Horn Assembly
Corner Midrange Horn - Throat Of Horn Assembly
 After fitting is complete, all the joints will be sealed with a flexible caulk.
















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