SmallSyns, sealed box version, general cabinet plan.
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- Lilian Anthony
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1 4.275" 8" 6.2" 4.5" 4.65" 8" 15.00" 4.5" SmallSyns, sealed box version, general cabinet plan. (more detailed drawings of each part to follow in later pages, with better-than-ikea directions!) 0.125"nom 20.5" 9.75" 2" 0.5" FRONT VIEWS (without/with grille): Baffle (0.5" x 19.5 x 14.0) 3.90" CL 19.5" 5.8" 1.46" BACK PANEL (as seen from front) showing locations of braces and stiffeners SIDE VIEW showing internal construction (without horn or drivers): Vertical brace (2x) 0.375" 9" Vertical brace (2x) Cross brace Horizontal brace (2x) Center stiffener mounting blocks ( Horizontal brace (2x) ¼ x19.3"x13.8" Sub-baffle A Baffle (0.5" x 19.5" x 14") Center stiffener 1/2 x1"x2.2" mounting blocks ( ¼ x19.3"x13.8" Sub-baffle B ¼ x7.25"x7.25" Spacer with 5.75"D centered hole Felt damper (2x) 1/2 x1"x2.2" cross brace Dimensions shown assume that half inch nominal ply is 0.50" thick, quarter inch panels are 0.25" thick
2 SmallSyns, sealed version: ½ ply panel cuts (for two speakers, from three 24"x48" panels) 19.5x14 (baffle/back, 19.5x14 (baffle/back, 7.1x14 (vert braces, Grain runs this way 19.5x9 (top/bot, 19.5x9 (top/bot, 7.1x6.8 Horiz. br. 19.5x14 (baffle/back, 19.5x14 (baffle/back, 7.1x14 (vert braces, 19.5x9 (top/bot, 19.5x9 (top/bot, 7.1x6.8 Horiz. br x9 (sides, 15.25x9 (sides, 15.25x9 (sides, 7.1x6.8 Horiz. br. 7.1x6.8 Horiz. br. 2x19.4(cross brace, 2x) 2x19.4(cross brace, 2x) 15.25x9 (sides, 7.1x14 (vert braces, 7.1x14 (vert braces, 2.2x1.25 (mounting blocks, 8x) 4.90x1.25 (center stiffeners,
3 19.3x13.8 (sub-baffles, 19.3x13.8 (sub-baffles, 19.3x13.8 (sub-baffles, SmallSyns, sealed version: 1/4 and 1/8" panel cuts For two speakers. 1/4 MDF or Plywood, from two 24"x48" panels: ~48"x~24" 19.3x13.8 (sub-baffles, 6.5" x 6.5" (xover, 7.2" x 6.5" (Spacers, 6.5" x 6.5" (xover, 7.2" x 6.5" (Spacers, 6.5" x 6.5" (xover, 7.2" x 6.5" (Spacers, 6.5" x 6.5" (xover, 7.2" x 6.5" (Spacers, For spacers, cut out holes with jigsaw before cutting pieces from larger panel! ~48"x~24" For two speakers. 1/8 ply or 0.063" FR4: 4.35"x4.45", 2x, for midrange mounting panels cut out holes with jigsaw before cutting pieces from larger panel!
4 0.85" SmallSyns, sealed version: SEOS15 waveguide modifications 4.35" Midrange Mounting Panel. material: 1/8" ply or 0.062" FR4 circuit board stock 0.60 " 3/8"D Relocation of tweeter compression driver mounting holes Cut off lower corner around driver outline with jigsaw. Approx 0.1" 1.75"R 4.45" Drill 8x approx 0.125"D holes approx where shown to improve epoxy grip Center driver on upper end of panel, mark mounting holes positions with pencil. Draw cross lines between hole center locations to find the center. Draw 1.75" radius circle using compass. Cut out the circle using jigsaw. Drill small holes for sheet metal screws for driver mounting 0.90" 7/16"D (See instructions)! (measured along horn body)
5 6.8" 14" 5.85" 7.6" 7.6" 14" 3.7" 3.75" 7.2" 6.5" 4.5" SmallSyns, sealed version: Machined wood piece details Baffle ½ preveneered plywood (1/2 x19.5"x14") Trace around SEOS15 Horn for opening 19.5" CL CL 2" 9.75" 0.5" holes 11/32" Dia., or as required for damper (2 places) Cross Brace ½ x2"x19.4" Spacer detail (2 per speaker) ¼ material 3.25" 5.75"D 6.5" 0.35" holes 7/32" Dia. (6 places) Hole positions and outline to be traced from woofer Sub-baffle A detail (¼ x19.3"x13.8") 2.75" 1.15" Opening 3"x2.2" (for # terminal cup) 1.5" Back, ½ pre-veneered plywood ½ x19.5" x 14" Vertical Brace detail (2 per speaker) 1/2 material 8.25" Sub-baffle B detail (¼ x19.3"x13.8") 3.55" 1.15" 7.1" Horizontal Brace detail (2 per speaker) 1/2 material 7.1" Center Stiffener (1 per speaker) 1/2 material 4.9" 6.75"
6 4.65" SmallSyns, sealed version: Baffle Assembly 1) Place baffle face down 4) Mark and drill holes for woofer apertures on front of baffle, cut aperture outlines with jigsaw. (Cut through all three panels) Radius= " (7/8" D) 8 places DRILL AND CUT AFTER LAMINATING BAFFLES AND SUB_BAFFLES 3.90" 5.8" 1.46" 2) Glue sub-baffle A to back of baffle. Make sure that subbaffle A doesn t extend beyond outside edges of the main baffle. 5) Glue the two spacer panels on the back of subbaffle B, so they center on the woofer apertures 3) Glue sub-baffle B to back of sub-baffle A, making sure that sub-baffle B doesn t extend beyond outside edges of the main baffle. Clamp all three panels together (using wax paper on sensitive outside surfaces) until the glue cures. 6) Drill with 1/16" Dia bit from the back, through baffles, centered at spacer holes (12 places). Drill with baffle face against a scrap surface to avoid splintering. Then inset holes from front (or bevel to use flathead screws). Finally, drill through with 7/32"Dia bit to for woofer mounting screws.
7 6.2" 8.5" Up SmallSyns, sealed version: Pencil guideline marking 3.2" 7.3" 7.3" (bottom) Front
8 Up Up Up Up SmallSyns, sealed version: Mounting blocks and Braces Assembly 1) Glue 2x center stiffeners and 4x mounting blocks above guide lines where shown. All these stand on 0.5" thick sides, to from the surface of the back panel. Avoid glue beads at ends of the stiffeners and at lower edges of blocks where marked. Keep the two side mounting blocks to just inside the edges of the back panel. Allow glue to set. 3) Glue 2x horizontal braces to the back panel, vertical braces, and mounting blocks as shown. If necessary, trim or sand the inside ends of the horizontal braces to assure that the outer ends align with the outer edges of the back panel! Clamp the braces to the blocks where shown, keeping them firmly against the back panel until glue sets. (If deep enough clamps are available, also clamp the braces to the back panel where marked with bullseyes). 2) Glue 2x vertical braces to the back panel and to the center stiffeners. Make sure the ends of the braces align with the outer edges of the back panel! Clamp the braces to the stiffeners where shown, keeping them firmly pressed to the back panel until glue sets. (If deep enough clamps are available, also clamp the braces to the back panel where marked with bullseyes). 4) Install felt dampers (2x), then glue Cross Brace at 4 places, and clamp. Assure the cross brace does not extend beyond outer edges of back panel.
9 Up SmallSyns, sealed version: Outside Panel Final Assembly (front view) (side view) (front view) (side view) 1) Glue bottom to back and to the vertical braces. Clamp braces at front and back panel at back to the bottom. Assure that the back is aligned, flush with and perpendicular to the bottom. 3) Check fit of top panel, if needed sand vertical braces or panels to minimize gaps. Glue and clamp top panel to baffle, back panel, and vertical braces. Assure top panel is aligned with back panel. The baffle should be inset approximately 0.375" from the top. (front view) (side view) (front view) (side view) 2) Glue the baffle to the bottom panel and to the horizontal and vertical braces. Clamp from front to back at the vertical braces. Assure that the baffle is aligned with and down against the bottom panel, inset approximately 0.375". 4) Glue and clamp sides to the cabinet. They should be flush with the top and bottom in front and extend approximately 0.125" above and below the front and back..
10 Front SmallSyns, sealed version: Passive Crossover #XXX-XX numbers are Parts Express part numbers Tweeter (top, inside) Baffle assembly 6.5"x6.5" (crossover board) 6.5"x6.5" (crossover board) Back panel Vertical brace Midrange Woofers Mount crossover components (except C5, R2) onto ¼ x6.5"x6.5" boards with hot-melt glue, connect together using component leads. Tweeter and Midrange crossover on one board, woofer crossover on the other. Put gasket tape on back of boards to prevent buzzing and, attach with ½ wood screws to the top panel If additional voicing is desired: Tweeter output will increase with increasing R1. Midrange output will increase with increasing R6. Presence region will increase with increasing C3, C SEE NEXT PAGE
11 SmallSyns: Crossover Voicing Adjustment Effects These parts can be varied to adjust for driver sensitivity variations or listener preference Changes shown are 0.5dB/division, relative to crossover parts as listed in the schematic R6 to 15 ohms C3+C6 increased 0.3uF R1 to 33 ohms R6 to 3.3 ohms C3+C6 decreased 0.3uF R1 to 7.5 ohms
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