HI-VI M4N / PEERLESS 811582 SURROUND
SPEAKERS
1. Cut 2 front
panels to size as specified in the "Box" section, using 0.50" thick
MDF. The dimensions should be 10.25" high X 23.50" wide.
2. Route the driver openings.
3. To cut the grooves that will allow the bending of the MDF, I used a 1/16" thick blade with a 7/16" height on my table saw, and moved the rip fence 0.50" between each groove. I cut a total of 7 grooves, one in the middle of the bending area, and 3 on each side.
4. Angle the blade of the table saw to 45 degrees to bevel the panels. The bevel should be on the same side as the grooves.
5. Soak the grooves in water until the MDF is saturated through out before any bending is done.
6. Note disaster when
soaking time is not sufficient before bending. It's a total PIA when the whole
thing has to be done again - routing, grooving, and
beveling.
7. Glue and clamp
front panels to back panels.
8. Pour glue copiously
on grooves to strenghten bent areas. Fill gaps, holes with wood putty and
proceed with sanding.
9. Assemble crossover.
Make sure that the crossover can fit through the midwoofer opening for easy
installation and removal. The topology used is a 2nd order LR at 2,500 Hz with a
impedance compensation network and a 6dB L-pad on the
tweeter.
10. Prime the box with
2 coats of primers to seal the MDF, then spray on your favorite color. I used 4
coats of metallic blue Rust-Oleum to match the ceiling color of the home
theater.
11. Install crossover
inside box. I use 1/2" spacers to isolate the crossovers from the back
panel.
12. Install the
midwoofers and tweeters. All drivers are installed in
parallel.
13. Cut MDF to make the top and bottom
panels, adding 0.50" in length to the front only. The back of the top and bottom
panels should be flush with the back panel of the box, so the speaker can be
installed flush against the wall.
14. Use a 1/4" roundover bit to route the
front edges of the top and bottom panels.
15. Prime and paint black.
16. Glue and clamp to box until
dry.
13. ALL
DONE!