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PostPosted: November 3rd, 2022, 2:24 pm 
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Joined: July 25th, 2013, 9:41 am
Posts: 78
Pursuant to Jim's suggestion, I figured I share a horn speaker I built for my brother at the end of last year (but just finalized crossover work a month or so back). The final crossovers have yet to be built.

The horn was designed by Joseph Crowe. The planner driver used is the GRS PT6825-8

I decided to go with my own woofer choice (Dayton Audio - DSA-315-8) and my own crossover.

The final picture shows them on the inside of the other speakers in the room. After Jim came and auditioned the speakers, he suggested I move them further apart (now they are on the outside). This resulted in a HUGE improvement in soundstage/presentation. Almost night and day.

For those interested, some pictures below:

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Last edited by dkalsi on November 3rd, 2022, 3:40 pm, edited 1 time in total.

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 Post subject: Re: Horn Speaker Build
PostPosted: November 3rd, 2022, 2:50 pm 
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Joined: July 8th, 2016, 4:34 pm
Posts: 580
Someone really likes Baltic Birch plywood. What is the horn driver?


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 Post subject: Re: Horn Speaker Build
PostPosted: November 3rd, 2022, 3:25 pm 
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Joined: July 24th, 2015, 4:17 pm
Posts: 1709
Location: Parkville, Maryland
FINALLY! Someone is using acoustic fill other than that damn reactive polydacron. :thumbup:

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 Post subject: Re: Horn Speaker Build
PostPosted: November 3rd, 2022, 3:41 pm 
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Joined: July 25th, 2013, 9:41 am
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brombo wrote:
Someone really likes Baltic Birch plywood. What is the horn driver?


Hahah - my woodshop is in my basement, so no MDF is allowed in the house.

The horn driver is the GRS PT6825-8


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PostPosted: November 3rd, 2022, 4:10 pm 
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Joined: July 8th, 2016, 4:34 pm
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Are you putting a back volume on the horn driver to balance the horn impedance? What is the crossover frequency?


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PostPosted: November 3rd, 2022, 5:34 pm 
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Joined: July 25th, 2013, 9:41 am
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I believe the rear chamber is approximately 7 liters and fully stuffed. The crossover frequency is about 500hz.


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PostPosted: November 3rd, 2022, 5:42 pm 
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Joined: July 8th, 2016, 4:34 pm
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Very nice! Did you think about laying up the horn with fiberglass cloth on a form for a smooth curve?


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PostPosted: November 4th, 2022, 9:50 am 
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Joined: February 19th, 2017, 9:43 am
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Regardless of how this sounds, you clearly have incredible wood working skills. Impressive!

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PostPosted: November 4th, 2022, 10:09 am 
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Joined: February 28th, 2013, 1:19 pm
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Super impressive mitering. I assume you use CAD to figure out all the angles and resultant layout. What is not apparent (and equally important) are the jigs needed to both cut the wood accurately AND hold the pieces in alignment and clamped during glue-up. Everything can fit together dry just fine, but once you put glue on the joint, and start applying clamping pressure, it moves all over the place. This takes as much planning as the cuts. This is masterful work!!!

David


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PostPosted: November 4th, 2022, 10:52 am 
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Joined: July 25th, 2013, 9:41 am
Posts: 78
Thanks Dave/David,

One can purchase the plans directly from Crowe's website - and it has all the details one would need to cut the individual pieces. What's awesome is now he has plans available for 18mm plywood. He previously only had plans for 24mm, and I had to recalculate dimensions myself to figure out how I would build with 18mm.

All pieces were cut on the miter-saw. Believe it or not, the woodworking part wasn't difficult, but understanding how each piece needs to be positioned on the miter saw was certainly a challenge.

Gluing the three petals of the horn flare also wasn't difficult (just used tape + wood glue), but gluing all four completed petals together was very challenging (jigs needed to be made, and I also used construction adhesive + brad nails). The construction adhesive allowed for a longer set time and has gap-filling properties.


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