Wednesday, April 20, 2016

New Project - A Pair Of Matching Straight Midrange Horns

I built the New Folded Corner Midrange Horn with the intent of eventually building a second matching one for stereo. However, I have decided to build a pair of Straight Midrange Horns with the same flare rate as the original New Folded Corner Midrange Horn. The main reason for this is that I want to compare the New Folded Corner Midrange Horn with a Straight Horn version. The second reason is that the New Folded Corner Midrange Horn is so efficient, being corner placed, that it is several dB louder than the New Folded Corner Bass Horn with the KLH CL-3A woofer. The third reason is that I want to apply the same construction technique to a stereo pair of Straight Midrange Horns that I used with the Straight Bass Horns, otherwise known as the Sound Transformer Stereo Pair. I decided to build all of the parts at once for two Straight Midrange Horns. Here is the progress so far.

Pair Of Matching Straight Midrange Horns - All Sixteen Ribs Cut Out On Band Saw
Pair Of Matching Straight Midrange Horns - All Sixteen Ribs Cut Out On Band Saw

The band saw curved cut requires some attention to "leave the line" and not take too much.  Actually, before cutting the curved sides, I cut both ends of the identical ribs at the correct angle on a chop saw.  I used pine scraps I have had here for quite a long time.  After cutting the sixteen ribs, I clamped four at a time and sanded the curves to remove variations due to a "wandering" band saw cut.  Here is the setup using clamps and a sanding block.


Pair Of Matching Straight Midrange Horns - Four Ribs Clamped For Sanding
Pair Of Matching Straight Midrange Horns - Four Ribs Clamped For Sanding
These ribs will hold the sides of the mouth flare of the Straight Midrange Horns.  The mouth flare length is one-half of the Straight Midrange Horn total length.  The mouth flares will have a square flange at each end.  The smaller, narrower "throat" portion of the Straight Midrange Horns will also have a flange at each end.



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