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PostPosted: 09 Oct 2011, 05:20 
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Joined: 17 Aug 2011, 06:05
Posts: 236
Location: Australia
Rather than polluting other good peoples threads figured I'd start my own.
Effectively I grabbed a pair of the Fostex FE206En, and have put (so far) one enclosure together.

Here are the results of my efforts of the last couple of days :

Image

fairly complex chambers
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the whole thing
Image

i think i've got a complete one on the phone, will put it up in a minute.

my recommendations on this :

1. if you don't have skills with wood working - don't even attempt this - give the plans to cabinet makers and get them to build them for you.
2. if you are skilled with wood working, prepare for a couple of long days. i cut my wood by hand (well 99% of it) - i have a couple of circular saws (oh the exception to is the round holes - they are done by jigsaw)
3. prepare for ALOT of sawdust
4. i used 16mm particleboard as i am trying to stay away from MDF (cancerboard)

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PostPosted: 09 Oct 2011, 16:01 
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Joined: 14 Feb 2010, 13:13
Posts: 711
Location: Lisbon, Portugal
Amazing job!

They are looking very good so far! :)


Cheers,

Miguel


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PostPosted: 09 Oct 2011, 17:09 
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Location: Australia
thanks miguel :)

heres a picture of it standing upright on my work table. note these things are BLOODY heavy. i have only built one - i'll show progress and step by step on how to build the other :)

Image

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PostPosted: 10 Oct 2011, 01:31 
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Joined: 17 Aug 2011, 06:05
Posts: 236
Location: Australia
OK,

To do this you need the following

1. Patience
2. Rulers
3. Jigsaw, Circular Saw or Hand saws
4. Clamps
5. Wood glue
6. Nails
7. Lots of screws
8. Patience - see 1
9. The Fostex FE206En instruction sheet.
10. Wood. I used 16mm particle board/chipboard. I think you could get away with 1 x 1800x450 and 3 x 1200x450 pieces (about 40 bucks AUD)

Your end result should look like this (minus the sawdust, wood glue, sheet and other paraphanalia)
Image

Aforementioned Fostex instruction sheet and Selleys Aquadhere - best glue for wood I have worked with
Image

Step 1. Cut your wood.
Yes - cut all the wood as per the instruction sheet. Measure twice, cut once. Measure more if you like. Cutting this by hand takes a long time - I grabbed a battery powered circular saw which is nowhere near as savage as my electric one. That had me cut the entire thing out for the 2nd speaker in 2 hours. Not bad going. Doing it by hand I reckon added at least 2 hours to the job. When you are finished cutting you will end up with a tonne of sawdust and something that looks like this (also known as a 'flat pack' I believe)
Image

More to follow...

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PostPosted: 10 Oct 2011, 05:15 
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Joined: 17 Aug 2011, 06:05
Posts: 236
Location: Australia
OK, as promised.
Start by building this little guy
I won't go into details, other than screw and glue
Image

Time for the base (no, not bass)
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and I clamp the piece in my workbench, and, screw and glue, you get the idea
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My extra pair of hands helping
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And we have a base. Put it aside - let dry overnight
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One chamber wall
Image

The other chamber wall
Image

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PostPosted: 10 Oct 2011, 05:21 
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Joined: 17 Aug 2011, 06:05
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Location: Australia
Heres my compass - for the main driver panel ;)
Image

Hows it work? Find the center, nail it in, then the other nail acts as a scribe. Then use a pencil to color it in so follow with the jigsaw - helped again coloring in for me
Image

Drill a hole for the jigsaw, get jigsawing
Image

Attach the piece to the bottom of the main driver board
Image

Add the piece to go between the main driver board and the first chamber - screw and glue
Image

Flip it over, add the piece at the bottom of the main driver board plenty of glue and a couple of screws
Image

Clamp down, screw it together. I would nail but screws tension the pieces of wood together - the nails don't. You could use nails on opposite angles to each other
Image

And here you go
Image

Hope you enjoy, more installments tomorrow. My helper had to go to bed :)

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PostPosted: 11 Oct 2011, 05:16 
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Joined: 17 Aug 2011, 06:05
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Location: Australia
helper cracked the shits because the dog got his shoe and he wouldn't get it off the dog and i had to do it. oh well

so, the main driver board, needs its additional piece on. another round hole scribed out by my compass, and voila
Image

now the fun begins. lay out a side. lay the main driver panel down on it and mark around it
Image

drill holes ect on the board
Image

screw and glue
Image

next chamber on the back. another screw and glue. i lay the piece down, mark around it, predrill the holes, then glue, put the piece back down, and screw the whole shebang together
Image

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PostPosted: 11 Oct 2011, 05:21 
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Joined: 17 Aug 2011, 06:05
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Location: Australia
support bracket in place
Image

next bit, marked out, predrilled and glue in place
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in place
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because i like a challenge
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time for the base to go on
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screwed and glued in place
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time for the 'steps' as my son calls them, 120mm from the bottom of the main driver board, 125mm from the front. mark it out, pre-drill
Image

screwed and glued in place
Image

almost there
Image

a couple of challenges tonight stopped me from completing this, but, tomorrow (night) is another day.....enjoy

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PostPosted: 11 Oct 2011, 22:05 
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Joined: 08 Aug 2009, 03:11
Posts: 2229
Location: Chilliwack, BC
Very neat work you've done! :D

I like the way you did the baffle.... every time I've tried to use a router on K3, I ended up ruining it :blush:

Cheers!

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PostPosted: 12 Oct 2011, 02:47 
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Joined: 17 Aug 2011, 06:05
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Location: Australia
Gregg ; you really can't use a router on particleboard with great success ; if will come apart in most situations.
My tools here are a jigsaw, drill, hand saw and battery powered circular saw

Alot of work to get this far, furthermore I now have to figure out how to achieve a piano black finish. I think this will be with body filler (bog), hi fill, primer and GMH subframe black - and alot of coats of clear

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