teamSPB Project D*FN U - 4 SMD 18's,SPL D 25kwrms,16v,Air ride, PC, Carsson rims!

teamspb
Junior Member

35

06-12-2018, 04:09 PM

#11

45deg bits were cut (Cheers Andy!)
[Image: DSC05864.jpg]

Such a simple job...but so much messing around to getting the angles to meet up...where the 45deg angles from the floor meet the verticles!
[Image: DSC05899.jpg]

FG'd in place
[Image: DSC05908.jpg]

This bit was yet ANOTHER overkill...but I wanted to do it for piece of mind! Filling the gaps in the 45's with expandy foam
[Image: DSC05911.jpg]

Then all the corners were smoothed over
[Image: DSC05915.jpg]

teamSPB

teamspb
Junior Member

35

06-12-2018, 04:12 PM

#12

45deg bits were cut (Cheers Andy!)
[Image: DSC05864.jpg]

Such a simple job...but so much messing around to getting the angles to meet up...where the 45deg angles from the floor meet the verticles!
[Image: DSC05899.jpg]

FG'd in place
[Image: DSC05908.jpg]

This bit was yet ANOTHER overkill...but I wanted to do it for piece of mind! Filling the gaps in the 45's with expandy foam
[Image: DSC05911.jpg]

Then all the corners were smoothed over
[Image: DSC05915.jpg]

teamSPB

teamspb
Junior Member

35

06-12-2018, 04:13 PM

#13

Box was resined with 2-3layers internally...
[Image: DSC05920.jpg]

Then I built this
[Image: DSC05874.jpg]

teamSPB

teamspb
Junior Member

35

06-12-2018, 04:13 PM

#14

3 Layers in total make up the front baffles...

[Image: DSC05953.jpg]

The inner most edge has a 1/2" radius to help air flow at the back of the woofer
[Image: DSC05952.jpg]

Offering up the baffles to make sure they fit
[Image: DSC05937.jpg]

The weird cut outs I showed you before, are the braces for the inside of the box as well as the magnets as the subs weigh around 40-50kgs EACH! Not only are the 18" in diameter....they are nearly 16" DEEP!!!! Imagine the leverage weight on that!

[Image: DSC05867.jpg]

And test fitted with the port
[Image: DSC05867.jpg]

The back panel was then glued up
[Image: DSC05885.jpg]

And joint the rest of the box!
[Image: DSC05889.jpg]

Time to strengthen the top of the box!...An extra 2" of MDF going in
[Image: DSC05906.jpg]

teamSPB

teamspb
Junior Member

35

06-12-2018, 04:14 PM

#15

Third layer added...now 5" thick on the top...
[Image: DSC06003.jpg]

And the gap was expandy foamed
[Image: DSC06005.jpg]

And I made sure it was JAM packed in there
[Image: DSC06006.jpg]

The inside of the box was then Gelcoated black for a SUPER SUPER smooth finish!
[Image: DSC05922.jpg]

Time for some terminals!
[Image: DSC06054.jpg]

8g Knu Konceptz power cable should be up to the job for speaker cable me thinks!
[Image: DSC06027.jpg]

Crimps on

teamspb
Junior Member

35

06-12-2018, 04:14 PM

#16

teamSPB

teamspb
Junior Member

35

07-12-2018, 09:37 PM

#17

Oh and look what finally made its way to see its new home LOL
[Image: DSC06074.jpg]

teamSPB

teamspb
Junior Member

35

07-12-2018, 09:37 PM

#18

Right, now that we had the baffles and the braces cut...it was time the braces went on a diet...

Firstly the middles had to be cut out so the magnet could slide through and rest on the brace...then secondly, MDF was removed from the brace...just enough so there was still plenty of MDF remaining to support near on 80-100kgs of weight on there own!

So they went from this
[Image: DSC05874.jpg]

To this

To this

Again, were put into the box to make sure they fitted nice and snug...so snug I needed a sledgehammer to get them straight up!
[Image: DSC06076.jpg]

Now, it was make or break....should I of aligned the brace wrong, drilled any centre points wrong...or just been plain silly...the magnets WILL NOT line up with the holes in the braces Sad

...and would you believe it...

IT FITS!!!!!!!!!!!
[Image: DSC06059.jpg]

Now, If you have never picked up an SMD before, you will NEVER realise how difficult it is putting one of these in a wall! Lifting them up and down aint a problem...its holding them while they are horizontal where the problems come in! At this point, we needed 2 of us to lift, push and guide the sub into its 'test home'!!! (Cheers goes out to my Dad here for the hand!)

Heres 'SMD #99' chillin...looking proud!
[Image: DSC06038.jpg]

teamSPB

teamspb
Junior Member

35

07-12-2018, 09:38 PM

#19

Time to get the braces in to firstly, support the subs, and secondly brace the box BIG time!

Get some angle steel (which is rated at over a ton IIRC!)
[Image: DSC06062.jpg]

Cut it to the right lengths
[Image: DSC06142.jpg]

Bond it to the wood
[Image: DSC06079.jpg]

Then screw the steel to the MDF using HEAVY duty coach screws
[Image: DSC06078.jpg]

teamSPB

teamspb
Junior Member

35

07-12-2018, 09:38 PM

#20

Time to fit the braces!
[Image: DSC06081.jpg]

As you can see from the pics, the braces are 2" thick themselves...and are braced further by the steel sections...I dont think this will flex! If it does, ill be in serious shock! Steel/MDF is bracing the side panels, the port, the floor AND the roof!!

Port was also specc'd and radiused...
[Image: DSC06110.jpg]

teamSPB

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