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I'm not going to be as detailed on this page as very little differed between the construction of these subs and my original Tempest. So any information not here can be found either in the Tempest portion of my site of at Patrick Sun's web site.
The final dimensions decided upon for the twins project were as follows:
The only thing different with the endcaps this time around was I left a slightly larger lip overhanging the sonotube and used T-nuts instead of the much more expensive widgets I used on my Tempest. The T-nuts were easier to work with and worked just as well. Don't know if it was necessary but I did use some bulldog glue when hammering the T-nuts in to make sure they wouldn't pop out. Was messy but I had no problems with them the three times the driver was removed and re-attached on the one sub.
One tip for the T-nuts, drill a hole just the right size for the T-Nut all the way through the endcap instead of drilling a hole just big enough for the screw all the way through and just a portion of the hole big enough for the T-nut. Makes threading the screws into the T-nuts much easier when mounting the driver.
The port differed on the twins a fair bit from my Tempest. Port kits with mounting flanges are a lot less work then mounting a straight piece of PVC pipe (although second time around with the PVC pipe wouldn't be all that bad). Just cut a 6.25" hole in the top endcap, hold the flare with the flange in place, drill pilot holes and you are done the construction part. After the endcaps are painted just screw the port in place and seal it up with some calking. Also as you can see in the second picture below the walls are lined with polyfill. There is around three layers in there that was attached using a staple gun to the top and bottom endcap.
However, given these subs were going to be much shorter than my Tempest I decided grilles on the ports would be a good idea. Simple enough to do with the Parts Express 8" grille. Just place the mounting hardware where you want it, drill pilot holes, then after you paint screw the mounting hardware in place. Then the grille just pushes on to the mount. Please excuse the finger prints and the flashes discoloring of the fabric.
This time I decided against mounting the amp to the enclosure. So screw in binding posts were used instead. They work slick. Marked out and drilled pilot holes for the posts to screw into. On the inside of the endcap used the widest straight router bit we had to cut a slot just over 3/4" deep. Then used a beveling bit to bevel the edge of this slot. After painting screw the binding posts in and use some crimp rings to attach some wire to them.
I also decided to put base plates on the twins as I just like the way they look better. The plate itself is just 1.5" of mdf cut to the same diameter as the outer lip on the endcaps. Rounded both edges over. Drilled 1/4" holes where the legs would attach. And drilled counter sink holes big enough for a 1/4" washer, lock washer and nut on the bottom side. The bottom endcap then has 1/4" threaded inserts attached were the legs would go. The legs are just 1.5" diameter round hardwood cut to 4" lengths. On one side they have 1/2" of 1/4" threaded rod sticking out and on the other side they have just under 1.5" sticking out. On both sides there is about an inch of threaded rod in the leg. When all used together results in a pretty solid mount for the base plate.
The sonotube, endcaps, base plate and legs were all primed with a dark grey primer (endcaps were in the sonotube at this point). Then the endcaps, base plate and legs were all painted flat black with spray paint. After the paint was dry the port was attached. The driver was wired in parallel and had closed cell foam weather stripping run around its' flange. It was then wired to the binding posts and screwed in place. The base plate was bolted on. Then the grille for the port was attached.
The sock this time was just ribbing, so no sewing required. Just cut to length and pull over. With that done the sub was fully completed. And this time around it only took 2 days. The first picture is the home of one of the subs at my parents place. The second is a pick of the home of the other sub in my roommates room. Yes the speaker placement sucks, but you are just a little limited for options in a 10x12 bedroom that also contains a L shaped desk, computer, bed and dresser. In a bedroom this small that sub sure does pound though. Regardless the roommate is hoping I find a job soon and move out so his stuff can be moved to where mine currently is.
Still to come (maybe).
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