Monday, September 21, 2015

New Folded Bass Horn - Progress

The inspiration for the New Folded Bass Horn project is the Klipschorn, designed by Paul Klipsch about seventy years ago.  The goal is a folded bass horn with lighter weight, wider frequency range, more accessible driver assembly, and versatility as bench seating and display shelving.

Yesterday, I cut some parts for the New Folded Bass Horn out of a 4' x 8' sheet of plywood.  I am starting with the throat construction of the horn first because it will not be accessible after the horn is completed.  Here is the throat, consisting of a central spacer web with two sides.

New Folded Bass Horn - Throat Construction
New Folded Bass Horn - Throat Construction
After assembling the horn throat, I set up the plywood sheet outside and cut out the next four panels for the next flare.  I used the throat assembly as a jig to check and refine the dimensions of the next four panels.  In the photo, upper left, is the horn throat assembly.  One panel is visible to the left of the circular saw.  I use the 4' straight edge and small clamps as a guide for cutting panels.  I am using a plywood blade with small teeth to minimize tearing up the plywood edge.


New Folded Bass Horn - Cutting out panels
New Folded Bass Horn - Cutting out panels
Finally, I set up the throat assembly for further assembly.  Here is a panel in position.


New Folded Bass Horn - Panel in position
New Folded Bass Horn - Panel in position
I use sheetrock screws to fasten the panels together while the glue is drying.  It is a little tricky maintaining the assembly square and free of distortion.  It helps that the plywood sheet is quite stable and flat to begin with.  All four panels are now glued and fastened.  This is a view looking into the horn throat.  You can see the end of  the center spacer inside the horn throat in the following picture.

New Folded Bass Horn - Looking Into Horn Throat
New Folded Bass Horn - Looking Into Horn Throat
 Here is the opposite end of the assembly, showing the center spacer extending about two inches beyond the side panels.


New Folded Bass Horn - Looking At Opposite End
New Folded Bass Horn - Looking At Opposite End
 Here is another view with the assembly set on the throat end.  At this point, the first 25 inches of the bass horn to the first fold are fully assembled.  There will be more to come as additional 25 inch lengths are added one at a time.


New Folded Bass Horn - Another View
New Folded Bass Horn - Another View
You will find more progress on this project at New Folded Bass Horn - More Progress.

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