Thursday, April 28, 2016

Progress On Construction Of The New Straight Midrange Horn

With the large flares of the New Straight Midrange Horn construction essentially completed, I begin construction of the smaller flares of the horns.  Using the same techniques employed on the Sound Transformer Bass Horns, a pair of flanges of the same dimension as the smaller flange on the larger flare are cut out on the table saw.  By beveling the edges of the square opening in the center, I will have the flange interior edge flush with the faired exponential expansion.  Four pairs of ribs are cut at the proper angle on the chop saw.  The ribs will be scribed to the exponential curve using a plywood pattern but only after they are fastened into position between the flanges.  To get the ribs to fit, it is necessary to cut away a bit at the small end of the horn.  Here is one of the horns set up for marking with the pattern.

New Straight Midrange Horn - Throat Flare Progress
New Straight Midrange Horn - Throat Flare Progress
After marking all four of the ribs for the curve as well as numbering the matching parts so they can be reassembled later, the rib curve is cut out on a band saw.


New Straight Midrange Horn - Throat Flare Progress
New Straight Midrange Horn - Throat Flare Progress
The series of small cuts to the line make it easier to "leave the line" without cutting away too much.  Here are the four ribs after cutting the curve.


New Straight Midrange Horn - Throat Flare Progress
New Straight Midrange Horn - Throat Flare Progress
Now, the horns are reassembled so the other two pairs of ribs can be positioned and marked.


New Straight Midrange Horn - Throat Flare Progress
New Straight Midrange Horn - Throat Flare Progress
All eight rub curves are sanded by hand to the line using a sanding block.


New Straight Midrange Horn - Throat Flare Progress
New Straight Midrange Horn - Throat Flare Progress
Here are the horns with all eight sanded ribs fastened in.  The cardboard trapezoid will be used to mark four plywood sides.


New Straight Midrange Horn - Throat Flare Progress
New Straight Midrange Horn - Throat Flare Progress
Here is one of the throat flares set on top of a mouth flare.


New Straight Midrange Horn - Throat Flare Progress
New Straight Midrange Horn - Throat Flare Progress
Tomorrow, I will cut the sides for the throat flare.

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