fEARful 15 Build: Neobassman

OK so here's some pics from the build of a by-the-book fEarful 15/6. Cut the plywood on a table saw. I'm using 12mm baltic birch, a 5'x5' panel. the plans use numbers, but I prefer letters for the pieces:

http://i264.photobucket.com/albums/ii182/neobassman/fEarful 15 Build/IMG_0251.jpg

Used my router and a quick n Dirty hole jig (scrap of lauan ply) for the driver cutouts:

http://i264.photobucket.com/albums/ii182/neobassman/fEarful 15 Build/IMG_0254.jpg

Baffle holes Cut. I'm not using a tweeter, so just two holes for the 3015 and the mid:

http://i264.photobucket.com/albums/ii182/neobassman/fEarful 15 Build/IMG_0256.jpg

I am using scoop handles and a recessed input panel, so i cut those holes, also, using a handheld jigsaw:

http://i264.photobucket.com/albums/ii182/neobassman/fEarful 15 Build/IMG_0257.jpg

Starting the assembly - I used PL Premium construction adhesive and a Air nail gun brad nailer to hold things in alignment. Here's the back braces in place:

http://i264.photobucket.com/albums/ii182/neobassman/fEarful 15 Build/IMG_0258-1.jpg

Most of the assembly is complete, here. You can never have enough clamps!

http://i264.photobucket.com/albums/ii182/neobassman/fEarful 15 Build/IMG_0259-1.jpg

Closeup of the midrange enclosure and clamping:

http://i264.photobucket.com/albums/ii182/neobassman/fEarful 15 Build/IMG_0262-1.jpg

Here's the next small step, installing the baffle:

http://i264.photobucket.com/albums/ii182/neobassman/fEarful 15 Build/IMG_0263.jpg

Filled holes, Rounded the corners with a trim router (1/4" qtr Round, to match the corner protectors I selected):

http://i264.photobucket.com/albums/ii182/neobassman/fEarful 15 Build/IMG_0268.jpg

I set the speakers in place and marked the mounting holes. I then drilled holes and pressed the t-nuts in place. I prefer to epoxy these in place so they are less likely to work Loose during mounting. The two up near the baffle brace/midrange box did not really fit, so I ground down the edges some to match the amount of space available (as shown in pic). The rest of them fit pretty well but stuck out a teeny bit into the opening. These probably would have been OK, but I decided to file off the bit showing just to make sure there were no problems:

http://i264.photobucket.com/albums/ii182/neobassman/fEarful 15 Build/IMG_0265.jpg

I'm going to put some kind of grill on this, but I spray-painted the baffle and the inside of the port with flat-black:

http://i264.photobucket.com/albums/ii182/neobassman/fEarful 15 Build/IMG_0271.jpg

With this, the box is pretty much done, except for the Duratex exterior coating, mounting the hardware, and of course the electronics. On to building the crossover. I've done electronics in the past but this is my first crossover from scratch. I'm following Greenboy's "cheap but good" crossover for the 15/6, as described on the fEarful Wiki here on TB. Here's the layout for the L-pad resistor on a scrap of 1/4" stock. In hindsight, I should have used plywood for this (for durability), but it worked ok:

http://i264.photobucket.com/albums/ii182/neobassman/fEarful 15 Build/IMG_0272.jpg

Here's the completed L-pad:

http://i264.photobucket.com/albums/ii182/neobassman/fEarful 15 Build/IMG_0274.jpg

...and the completed crossover, mounted on a scrap of 1/4" Luan using yellow tie-wraps to secure the components. It is not the neatest soldering job, and the 12 ga. wire is a bit of overkill, but it's what I had on hand:

http://i264.photobucket.com/albums/ii182/neobassman/fEarful 15 Build/IMG_0277.jpg

Here's the completed crossover, ready for mounting. I probably could have gotten this more compact and with fewer wires, but I think it will work fine and be reasonably durable. Also shown here are the nylon stand-offs and 1 5/8" drywall screws that I used to mount these boards to the top of the shelf above the port:

http://i264.photobucket.com/albums/ii182/neobassman/fEarful 15 Build/IMG_0276.jpg

Next came mounting the crossover panels in the cabinet. I also installed the Damping material (polyester fill, 4 layers held in place with a few staples):

http://i264.photobucket.com/albums/ii182/neobassman/fEarful 15 Build/IMG_0281.jpg

...and I set the drivers in place just to make sure everything seems to go together properly.

http://i264.photobucket.com/albums/ii182/neobassman/fEarful 15 Build/IMG_0279.jpg

• * *

Today I finished everything and tested out the cab. It sounds AWESOME! If you have any inclination to try a build yourself, I highly recommend it. Here's this weekend's work:

I was really skeptical about working with the Duratex. I thought it would be a goopy mess and not turn out nicely. Well, this stuff is as easy as latex paint - maybe easier since it's pretty Thick, about like mayonnaise, thought a bit more dense. Here's the product and recommended rollers. I bought two thinking I would use one for each coat. However, the stuff rinses out with water, so I ended up reusing one roller for both coats. I wish they sold this stuff in quarts - I used less than 1/4 of a gallon total for both coats.

http://i264.photobucket.com/albums/ii182/neobassman/fEarful 15 Build/IMG_0289.jpg

One coat was definitely not sufficient, but two covered the cab nicely. Some on TB have recommended priming the wood before the first Duratex coat, but I did not find this necessary:

http://i264.photobucket.com/albums/ii182/neobassman/fEarful 15 Build/IMG_0290.jpg

http://i264.photobucket.com/albums/ii182/neobassman/fEarful 15 Build/IMG_0291.jpg

I let the Duratex Dry several hours between coats and before moving on. It dried pretty quickly and allowed me to move on to installing hardware later the same day. Here are the handles and corners installed. These handles did not come with a gasket, so I used some black silicone sealant from the hardware store to seal the handle opening. I just ran a bead of the caulk around the face of the cabinet, just at the Edge of the opening. I did the same with the input panel in the back. I also added large rubber feet; I debated putting wheels on this, but it's not overly heavy so I'll use it for awhile like this to see if I need to bother with casters:

http://i264.photobucket.com/albums/ii182/neobassman/fEarful 15 Build/IMG_0294.jpg

I installed the drivers using black 10/32 allen-head bolts. the t-nuts were well-aligned for the 3015, but one of the holes for the midrange was slightly off. I cheated and filed the hole in the aluminum frame of the driver to get the bolt to go in straight. It did not take much, and it really is not noticeable on the finished box. The 15" comes with a Thin gasket around the back of the lip for face mounting. the midrange, however, did not have a gasket on the back side. So, after making sure everything worked ok, I sealed the driver into the cabinet with a very small bead of the black silicone. It will make removing the driver more difficult if I ever have to remove it, but I think it is worth the possible hassle to get a good seal. Here's the finished unit, except for a grill:

http://i264.photobucket.com/albums/ii182/neobassman/fEarful 15 Build/IMG_0296.jpg

I debated what to do for a grill. Since the box turned out pretty well, I splurged on a custom-cut grill from "Reliable Hardware." Once the grill is in place, I'll post a final picture. In the mean time, this thing rocks with awesome sound. I love the way it reproduces the B's on my fretless 5 Tom Clement (shown below). It makes plenty of noise with my Genz-Benz Shuttle 600, enough to rattle the whole house. Can't wait to gig with it. This is my first cabinet with a 15" and I am really pleased with the sound, based on my initial tests. If this works out well, I think I'll probably ditch my Eden 210XLT which is half the size but much heavier...

http://i264.photobucket.com/albums/ii182/neobassman/fEarful 15 Build/IMG_0297.jpg