Finished

Final completed product

PWK class week-5 2011 term 3

During week 5 I started to foam my first speaker box. The process includes cutting the sheet's of foam to the right size and form and staple them into the pre-constructed boxes with a staple gun.

Problem encountered?: The awkwardness of stapling upside-down when putting the foam in.

Solved?: I learnt to live with it.

PWK class week-4 2011 term 3

During week 4 I started to think about how I am going to foam my boxes and have filed the wood out the sections of wood where the connections from the speaker cones and crossover are so the speaker cones sit flush.

Problem encountered?: ?

PWK class week-3 2011 term 3

During week 3 I unwrapped the strops and news paper from my boxes. I then started to sand them to get the excess glue off of the exterior of the cabinets.

Problem encountred: I sanded to hard in one section of the back and the Mighte'd joint is showing.

Fixed how?: I don't really mind but I may cover it up with the stain I'm using.

PWK class week-2 2011 term 3

During week 2 of term 3 I glued/constructed my speaker boxes. The process included creating L clamps out of MDF to go on the sides of the boxes to create a larger surface area so the strops don't dig into the wood.

problem encountred: I drooped one of the front pieces so it has a 1x1 cm notch taken out of the corner

Solver?: I am going to use a filler/putty to fix the hole on the cabinet.

PWK class week-1 2011 term 3

Mr. Mac gave the class a brief over view of what's happening this term, what is expected of us and when the dead lines are.This term we should have the boxes complete, including cut out, foamed, glued, painted and our crossovers finished.

Crossover Design

^ A photo of the crossover being tested.
^ above is a image of the final crossover in my speaker.


Roland EGX-350 just before cutting process.
Roland EGX-350 during cutting process.

The above image is of a crossover where the depth was not set correctly.

The above image is of the circuit wizard design with a component layout.


The milling bit ^

The final PCB layout design.

2D design layout ready to be cut out. With extra annotations for the component layout.

^^ The above image is the Circuit wizard design for my crossover.

Finished speaker cabinet construction.

^^ Image showing the internal bracing for the Internal sound pressure.

^^ This images shows the back of the speaker box with the holes cut out for the port and terminal block for cabling.

^^This images shows the speaker cones in place but before I have stained my boxed Dark nut oak.
^^ The above image is the finished compiled speaker box units before staining and cabeling and without top panels in place.

Making a 3d box min solidworks.

This is the final Technical drawing for my speaker box/design.



This is a render of the speaker box I am building with a dark wood grain texture on it.^^

The above Print screen shows the port/rear hole being cut out.^^


This image shows me creating and placing the feet for the bottom of my speaker box.^^


this image shows my cutting out the front cone holes out for the mid range, woofer and tweeter.^^


This image shows the thickness of the wood I'm using which is 18mm^^



This image shows me creating the internal excluded space inside my speaker box.^^

PWK class week-11 2011 term 2

This week i cut the holes for my braces. There was a long waiting Que for the drills and cutters hence why it took so long to Finnish.

Problem In-counted: Some
Problem Solved: I found some tutorials on Solid-works
Next Steps: Start to render up my designs with Photo View.

PWK class week-10 2011 term 2

This week I started on cutting out the pieces of my box. I have cut out the sides and the next step is to cut out the top and bottom pieces.

PWK class week-8 2011 term 2

This week i started cutting out the main pieces of my box. These include the left and right sides, the tops and bottoms and the front and back pieces for both boxes. We use the table saw to cut up all the wood under the supervision of our teacher, Mr Mac. The table saw helped me cut out all the wood fast and accurately. The table saw also allowed me to put a 45 Degree cut on the pieces of wood to allow for the miter joint.

Problem In-counted: The table saw still took awhile to set up for each piece of wood.
Problem Solved: I got a bunch of friends to help. In return I help them.
Next Steps: Help Friends and drill holes in the bracing wood.

PWK class week-7 2011 term 2

During week seven i finalized my cutting list and driver placements. the whole class discovered that the measurements being used were the exterior measurements so our volume calculations will be off seeing as the MDF we are using is 18mm thick. so logically you would lose 36mm on each measurement. this in turn will make the LT smaller so we would lose the sound quality we all would like.

PWK class week-6 2011 term 2

In week 6 I decided on my final design and design proportions to be at 18L of internal space.The two options we had for our types of wood were, MDF Or Marine Ply. The The Pro's and Con's Are, MDF is Good and consistent to build with, Easy to cut, Solid But looks bland. Marine Ply, is light, has a cool textures but is less solid and less consistent. I Chose I decided on 18mm marine ply for aesthetic reasons.

Next step: create a cutting list

PWK class week-5 2011 term 2

Week 5

This week I created a paper based representation of my speaker's to see what my final product will look(size wise) like.

PWK class week-4 2011 term 2

Week 4

This week we vainer-ed one side of our test boxes to create a feel for what the final product may look like.

problem occurred: I used way too much glue so the news-paper stuck to my box.
Fixed: When I build my final boxes I will know to use less glue.

PWK class week-3 2011 term 2

In week I finished my designs and created a front layout from A3 paper.

Problem I came across: I realized that the woofer was to small for the box and looked a bit weird having this little woofer in the middle.

Solved: I made my box 25mm smaller but 30mm taller.

PWK class week-2 2011 term 2

In week 2 I finished my sanding and started and started my painting.

Problems I came across:
*When My painting was finished there where a lot of scarch marks -How I resolved this problem
: I now know to do a finish with a finer sand paper.
*My box was a bit out of proportion as I dropped it - How I resolved this problem
:I need to be more care foul next time.

PWK class week-1 2011 term 2

Mr Terry Hawking took one of our cases abnd tought us the inner workings of frequencies and crossovers
* The crossover's we are making are second order/3rd order crossover
*The capacitor is used to remove the lower frequency's from the tweeter and keep the lower frequency's in the woofer's
*The inductor is used to remove the higher end frequency's from the woofer and add them to the tweeter

PWK class week-11 2011

I have continued on my box as I have been researching different types of joints. I have also filled/bogged the screw holes and sanded them off. The original time i bogged it There was to little hardener so I scraped it out and did it again with more hardener. My box went together very well with little trouble.

PWK class week-10 2011

Week 10

- We started to build our boxes. We are using both Butt Joints and Miter joints to test how each one looks and how to put together. we are using 3.2 drill bits and self taping screws. We are pre-drilling the holes so that its easier to drill and so the box is also square. We glued the miter joints together and Bogged the holes.

Problem In-counted: Two holes on one side of the box splinted because i didn't drill deep enough before placing in screws.
Problem Solved: The teacher told me to drill two new holes next to the previous ones and bog the old holes.

To do- Sand down boxes.

PWK class week-9 2011

We continued our designs and cut out the sections of wood for our example boxes to get a realistic idea for the sizes involved with these speaker cabinets. I continued on with my designs and ceated a list of designs that i would

PWK class week-8 2011

We are doing our design work on A3 paper so we can get a understanding of different designs and proportions. We also did the Brief for this project so we could understand what we are to do over the next year.

Problem encountered: The design I was thinking of getting is to time consuming for the amount of time i have to do the designs and work over the next year.

Solved how?: I decided to use a easier design to create a easier project of myself.

PWK class week-7 2011

In week 7 I continued my research and started to put ideas onto paper as design concepts.

PWK class week-6 2011

In week 6 i continued on research and refined my research about woofers, tweeters, crossovers and ports.

PWK class week-5 2011

We continued our research on the materials that would be needed to build out products and the prices involved. I also researched the reasons and uses for having more cones in the speaker EG: high volume output and quality.

PWK class week-4 2011

We continued our research and also did out key factors brain storm and key factors chart.

PWK class week-3 2011

We where given our folders to keep our work in for the paper work of this year.
We also started our research on tweeters, woofers and crossover's.

PWK class week-2 2011

Organized out door research down in town. We then went down to the stores eg: Sound Expression, Pro-tel and Harvey Norma. We went down to town so we could get a better understanding of what speaker designs look like and a feel for the different sizes involved in the design and use of the speakers.

PWK class week-1 2011

Intro into course
Showed previous years work for slight inspiration. Found out what unit standards we are doing this year and what achievement standards we are doing. With lots of talking and group discussions about what we are going to do in this course this year.