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Cross-overs for DIY speakers: assemble your own or buy assembled?

dgwojo said:
Here's the pics of the crossovers I recently worked on, the first one is MJHAMMER's Altec Model 19 upgrade, and the second was mentioned earlier in this thread, both have excellent results, Dave. :music:
Here's the before and after of the scrapped out Santana crossovers I used, these fit the Model 19 and A7's without any alteration, Dave.

Altec_Santana_Xovers_02.jpg


Altec_Santana_Xovers_01.jpg
 
streckfu said:
I was looking at the PE cross-overs that they sell assembled and wanted to ask how well they work/sound when compared selecting individual components and building your own. It looks like the pricing works out to be about the same or a little less than buying individual parts and assembling them....

PE cross-over

Anyone have experience with using them in projects?

Streckfu,

By far rolling your own crossovers yields tremendous results :yes:

I discovered just how good a high efficiency speaker can be when I needed a speaker to test run my DIY designed powerfull 10 watt SET monoblocks.

The results of which were stunning to me to say the least!

I took a 1200$ new Klipsch Forte and made it yield 5000$ performance using the worlds largest manufactured 8ga. inductors and some of the worlds finest caps

I decided that the best sound would be from crossover that is not subjected to internal acoustic energy because of microphonic properties of electronic componets and I wanted to have a platform that would allow me to voice many brands of caps and inductors if I chose to and yet have great looks and performance.

I spent 400$ on my Fortes and some 800$ on my crossovers and wire the Fortes are internally rewired as well.

I have had several people hear these and just on ebay and purchase Forte's for 4-700$ Just replacing the stock caps with high quality ones is a major improvement for the mid and top end of the speaker.

0000030mb6.jpg


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I have the crossovers on the floor and not on the top of the speaker as pictured the componets are velcored in place and fastened with brass terminal blocks that use allen head screws these are all gold plated as well

The inductors are from North Creek Music

SET12
 
Thanks,

It was a lot of work but it paid off with great sound!

I am very sorry to hear of North Creek's end of supplying us hobbyist :tears:

But I am glad he is successful as an OEM :yes:

SET12
 
You need to have a pic of stock Forte crossover just for a good laugh.

And I thought I went overkill with my Chorus II crossovers.....those are serious.....
 
mhardy6647 said:
Not to start anything, but there are those who feel that complex crossovers can suck the life out of music, irrespective of the perfect frequency response, phase response, or impedance curve they may provide.

mhardy:

I think you have raised a very valid issue here.

If folks are merely going to separate frequencies like with the Dayton xovers, then I'd recommend they look in ACTIVE Operation (aka active bi-amping). This is where your amps drive the speakers directly with no passive elements, but you do the frequency separation at LOW POWER with active devices PRIOR to the power amps. Then for 3 way systems, you could build a very simple xover just for the tweeter.

On the other hand, if you are planning on some frequency shaping as Mark described then that is a totally different story. What Mark is recommending is tailoring the xover network to correct for non-linearities in the drivers and cabinets. This is what the high quality speaker manufacturers do. It is, as Mark states, more complex, but the benefits can be well worth the effort.

Now a question for Mark.

Mark, supposing we went active for frequency separation. How difficult would it be to design and build strictly frequency compensation circuits? My “guess” is most of these will consist of simple cap and resistor circuits. Again, this is a guess.

Regards,
Jerry
 
onplane said:
mhardy:

Now a question for Mark.

Mark, supposing we went active for frequency separation. How difficult would it be to design and build strictly frequency compensation circuits? My “guess” is most of these will consist of simple cap and resistor circuits. Again, this is a guess.

Regards,
Jerry

Hi Jerry,

It would be much more straightforward than a whole crossover design, as you've guessed. Since the active crossover would be splitting the frequency for you, you could then just apply the frequency comp elements to the individual drivers. If you are using frequency comp on a woofer then you will probably need a zobel to level the impedance rise. Also, on a tweeter you will most likely need an LCR to deal with the impedance peak. This is unfortunate, but usually necessary as the frequency that you want to notch out is usually near the impedance peak in a tweeter. You need the impedance to be fairly level and well behaved to get a notch filter or bandpass to work well. I'm attaching a couple of simulations of a tannoy tweeter that I've been working on. It has a substantial peak in the 1khz to 2 khz region. I'll forego the crossover, and just put in the impedance comp and the frequency comp.

The first two figures are the raw impedance and frequency response. The second two figures are the impedance compensation circuit and compensated impedance response. The last two figures are the frequency compensation circuit (with LCR) and frequency compensated response. I haven't tried this yet, but I've certainly thought about it. The active crossover and separate amps solve some problems for sure, but I'm not sure if they would create others.

Mark
 

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Mark:

Thanks for the quick reply!!

I really like those circuits!! :thmbsp:

With resistance values in the 17 and 12 ohm range, this will create NO significant load for any amp.

Mark, just supposing under ACTIVE operation you put in only the frequency comp circuit? My guess this will help a little on leveling the impedance and it might be good enough.

Next, if you are designing a three way, you'll still need frequency separation between mid and tweeter. Notice that the mid requires only a low pass rather than a band pass. Mark, this just has to be simplier ... correct?

Regards,
Jerry
 
onplane said:
Mark:

Thanks for the quick reply!!

I really like those circuits!! :thmbsp:

With resistance values in the 17 and 12 ohm range, this will create NO significant load for any amp.

Mark, just supposing under ACTIVE operation you put in only the frequency comp circuit? My guess this will help a little on leveling the impedance and it might be good enough.

Next, if you are designing a three way, you'll still need frequency separation between mid and tweeter. Notice that the mid requires only a low pass rather than a band pass. Mark, this just has to be simplier ... correct?

Regards,
Jerry


Hi Jerry,

You could most likely get the frequency comp to do what you want without the impedance comp. It wouldn't be perfect, and it would require some fudging about, but you could probably get something that sounded very good.

With a three way, you do indeed still need the mid to tweeter crossover in there. And yes, it is a low pass filter rather than a bandpass on the mid. This is far simpler to design than a three way crossover, especially if you can manage to get the crossover point far enough away from either of the impedance peaks for the mid or tweeter.

Mark
 
Mike Stehr said:
You need to have a pic of stock Forte crossover just for a good laugh.

And I thought I went overkill with my Chorus II crossovers.....those are serious.....

I think the Altecs look great! A very nice job is done on those!

Here you go I have a CD for scale notice that it is about the same dia. as the stock crossover plate and crossover componets the large inductor is of course the low frequency inductor the other inductor being for the tweeter these are just stock componet values nothing was changed although the DCR's of the inductors are lower.

The Forte for having a passive radiator has very taut powerful bass I won't call it any where near world class bass ( that is bass with excellent pitch defination) but the Forte has a strength that has never called a need for a sub often people ask where is my sub and often are shocked to hear there is none and often further shocked when I tell them after I put some Rap on for them that they are listening to just 5.5 watts rms when their car stereo is usually several hundred watts then I usually get a statement like "How can that do that"

The midrange is very full lots of defination and body and life size imaging.

The top end is smooth and extended but very revealing of ambiant ques especially of relaying the recordings acoustic size.

Lateral imaging is nothing short of astounding imformation often extends 5-10ft left and right of the speakers thru the side walls they are about 9ft apart, Depth and layering are extordinary, Image height could be a little taller according to some listeners but more than enough for me.

Little did I know a few yrs ago that I would be listening to of all things a "Klipsch"

SET12

stockcrossovervsmodifiedkr9.jpg
 
As informative the posts have been as I have learned quite bit, they are far beyond my original question in posting this.

I was just asking if the retail Dayton (and other brand) X-overs on PE are satisfactory for basic speakers until I learn more about X-over design and construction.

The immediate use would be to put new drivers into an existing cabinet while trying to do this on the cheap. I just want to match a couple of drivers with a decent X-over so I can use the speakers.

I do not have the means to build $800 X-overs (though I do appreciate seeing what's possible) it's just a realistic as looking at a Ferrari.....I'm a winning lottery ticket away from either becoming a reality.
 
SET12 said:
I think the Altecs look great! A very nice job is done on those!

Here you go I have a CD for scale notice that it is about the same dia. as the stock crossover plate and crossover componets the large inductor is of course the low frequency inductor the other inductor being for the tweeter these are just stock componet values nothing was changed although the DCR's of the inductors are lower.

The Forte for having a passive radiator has very taut powerful bass I won't call it any where near world class bass ( that is bass with excellent pitch defination) but the Forte has a strength that has never called a need for a sub often people ask where is my sub and often are shocked to hear there is none and often further shocked when I tell them after I put some Rap on for them that they are listening to just 5.5 watts rms when their car stereo is usually several hundred watts then I usually get a statement like "How can that do that"

The midrange is very full lots of defination and body and life size imaging.

The top end is smooth and extended but very revealing of ambiant ques especially of relaying the recordings acoustic size.

Lateral imaging is nothing short of astounding imformation often extends 5-10ft left and right of the speakers thru the side walls they are about 9ft apart, Depth and layering are extordinary, Image height could be a little taller according to some listeners but more than enough for me.

Little did I know a few yrs ago that I would be listening to of all things a "Klipsch"

SET12

stockcrossovervsmodifiedkr9.jpg


Heres what I think you should do!

Look for a speaker you like then mod it by replaceing the stock componets with very high quality ones!

I think you will be able to do better this way then what my best friend was able to do against my Klipschs as he wanted to blow them away with a DIY design of his and he has some 30yrs of experiance! unfourtunately the klipsch held their own by a wide margine so a 1000$ worth of componets and labor are sitting in my basement because it wasn't as easy as he thought it was to beat them!

Just replaceing the stock caps is a major improvement in most older designs I go back to the days of Double large Advents of which in those yrs I owned at least 10 pairs the bass was powerful but I always craved more imformation then I discovered Dahlquist and enjoyed a wide deep sound stage and the great sense of space but the Dahlquist did not have the bass of the Advents

I went through many speakers but never have I had as much fun then when discovered these sleepers; with these Klipsch Fortes for 4-500$ investment used you'd be hard pressed to put together a DIY speaker to compete with these on the plus side at 98db/watt you can build some simple single-ended tube amps and have a great time lighting up you friends eyes with just 5-10 watts of power!

On a bigger note! I am thinking of a Super Forte project that is a new encloser with 4 active 12 in drivers two mids and two tweets for an SPL level of 104db/watt/speaker thats 8 active 12in drivers whew!!! Can we say "Deep Impact"

SET12
 
I think what SET12 says here is good because IMO a well designed crossover with stock parts sounds better than a generic crossover with expensive parts. (SET12 improves on this)

BTW, SET12, very impressive :thmbsp:
 
Thanks, Indm

I might add the the Klipsch drivers are all available yet and their is very high reguard for the Fortes yet even after nearly 20yrs since its introduction.

Again the Fortes have been one of the most pleasurable audio experiances in my 35 yrs of Audio experiance.

SET12
 
streckfu said:
Damn nice reply, Paul. Thank you.

My question was really motivated by curiosity as to whether the pre-fabricated X-overs are good enough for a low end DIY first project. I was thinking that for my first try, I would go for a more budget oriented set that way if I do make mistakes, It's not a big loss. Since I don't know much about X-over design yet, I could just use a retail item until I learn how to design my own.
Thus, would I notice a difference, with budget drivers, between the manufactured X-overs and building my own?
My advice would be to find a proven "recipe" from a proven design and build that as a first time project. While off the shelf crossovers work OK in the realm off high eff. stuff with horns and compression drivers, for speakers discussed here they really dont. One of many things not taken into consideration in these discussions is the natural roll off of the drivers. when using off the shelf drivers they must first be broken in and carefully measured. Relying on printed specs will lead to problems, rarely have I found a driver that consistently measures like printed specs. Once you know the actual response of your indiviual drivers can you properly design a cross over to work with those drivers. Installing a "12 db" 2nd order crossover with random drivers does not mean you will get 12 db per octave. some drivers may very well, depending on the selected crossover frequency, already be dropping off at 6db or 12 db per octave...adding an additional 12 db would result in either 18 db ( third order) or 24 db (forth order)...not 12 db. now your phase relationships between the two drivers are off and the srossover region is anything but smooth. Also, off the shelf crossovers will never make up for driver response abnormalities, like tweeters with peaks at their resonant frequencies, or mid ranges or mid woofers with rising responses, particularly kevlar or other stiff cone materials. To cure these problems, again, the drivers must be individually measured and then a crossover designed to correct for them. Many crossovers will appear to mix 6 db with 12 db or 18 db circuits (electrically) but when combined with the actual driver response results in the correct slopes at all crossover points. This is also the explaination for a lot of the cost of commercial speakers besides shipping, packaging,etc...The R and D to design proper drivers with proper crossovers and proper compensation built into said crossovers for the drivers chosen, and then get all the phase relationships between the drivers to be correct. This is sometimes why, as others have mentioned here, that sometimes you will see drivers polarity reversed compared to the other drivers. In cases like that, the phase relationship between the drivers is off 180 degrees (hopefully), so a driver is reversed. Putting together speakers is great fun, but throwing drivers in a box with an off the shelf, or designed from a chart of crossovers showing impedance and crossover point and slope does not result in those slopes, points or impedances (which vary wildly between drivers and frquency of any given driver), and the results suffer. Yes, many expensive speakers sometimes use surprisingly inexpensive drivers, but get great sound....but they have invested lots of time and money measuring those drivers and designing the perfect crossover for them. Similarly, buying expensive drivers and using off the shelf crossovers, or "chart designed" crossovers will give mediocre, and sometimes terrible results. Many "expensive" drivers have all sorts of frequency abnormalities that MUST be corrected through crossover comensation net works to glean the advantage of the driver. If one must use off the shelf parts, you want first, as simple a speaker as possible, i.e. 2 way instead of 3 way, and find drivers that are flat for a couple of octaves either side of the crossover point. ( not easy to do) Then, measure the impedance of the actual driver at THAT crossover point, and use your chart to come up with components for that impedance. Now, you may need some sort of ciriut across the woofer to hold its impedance as flat as possible through this region. Now, All you need is a tweeter with the same measurement at the same point...GOOD LUCK! at best, youi will likely end up with a compromise. Try threeway? it gets much more messy. the first speakers I built were based on the "select the drivers" and select a crossover, and for the money, didnt sound bad at all...but, once you see what can be had with a properly designed speaker the margin is not small. For all these reasons and more, I would work from a known recipe, from a designer ( like Joe Diappolito for instance) who has taken the time to get to know the drivers and has the skill and equipment to properly compensate the drivers, not just cross them over. This said, there are many speaker driver manufacturers out there who offer "recipes" that are no more than throwing textbook crossover in with their drivers. If you are not seeing compensation for resonant peaks, mixed slopes between drivers and other hints of an individually designed cross over for that specific application, you are probably being sold just a text book crossover. Yes it will work, but if you want to strive for true HIGH END results, "off the shelf throw togethers, while fun, will not get you there.

Russellc
 
MarkAnderson said:
Good reading, Paul. I actually learned a thing or two today :D . Thanks.
Again, using an 18 db crossover does not mean you will end up with 18 db crossover slopes, the ACTUAL response of the driver must first be known. This entire discussion presupposes that drivers are spot on their rated impedance and response extends smoothly through a few octave either side of the crossover region....this simply does not happen. As to having no reason not to use an 18 db cross over, well, there are many. One, is that as already stated, using an 18 bd "crossover" does not mean that is what you will end up with. Say for instance, you are building a two way speaker crossed over at 2500 hz. Lets say your woofer/mid range driver's response is fairly smooth and naturally falls off at 6 db per octave at 3500 hz. Adding an electically 12 db per octave crossover will result in 18 db per octave slope when combined with the natural 6 db slope of the driver, while if you had added an electrically 18 db per octave crossover would actually result in 24 db per octave. Plus, there are various different types of crossovers out there available in 6, 12, 18 or 24 db per octave. If used on both sides, the actual crossover point will sum differently at said crossover point for each of these different types. There is simply no way that throwing in a calculated crossover into a box with a couple of drivers is going to result in a proper blending of the drivers. This only begins the discussion, as phase, step respose, baffle width, lobbing, resonant peaks, and other myriads of factors needs to be considered to really properly meld drivers in a system, let alone get all there is to get out of the selected driver.

Russellc
 
lndm said:
Well put Russelc.

You mentioned the proven design. Here's a site with several fully documented designs by a guy that is thorough and knowledgeable.
http://www.zaphaudio.com/
Yes, this is the type of info that will result in a truely satisfying speaker, with out breaking the bank. Someone must do the r and d to design a system which properly mates the drivers and compensates for their various response qwirks. This can only begin after the drivers have been properly measured, in terms of response, impedance at various freqncies, resonant peaks and so forth. appears this chap has done so and lists the results of many of the drivers on this site. Going to this trouble can make the difference between a nice sounding ( or sometimes not so nice) system and a great one, whether one is using expensive or inexpensive drivers.

Russellc
 
SET12 said:
Thanks, Indm

I might add the the Klipsch drivers are all available yet and their is very high reguard for the Fortes yet even after nearly 20yrs since its introduction.

Again the Fortes have been one of the most pleasurable audio experiances in my 35 yrs of Audio experiance.

SET12
the path you took is another way....Improving a known properly designed system. Capacitors and so forth are a lot better than what was available 20 years ago. This way also uses a properly designed crossover, designed specifically for these drivers in a particular apllication. Klipcsh did the R & D, you improved on it. Agreed, this is much much more likely to give a proper result than throwing chart info into a box.

Russellc
 
streckfu said:
As informative the posts have been as I have learned quite bit, they are far beyond my original question in posting this.

I was just asking if the retail Dayton (and other brand) X-overs on PE are satisfactory for basic speakers until I learn more about X-over design and construction.

The immediate use would be to put new drivers into an existing cabinet while trying to do this on the cheap. I just want to match a couple of drivers with a decent X-over so I can use the speakers.

I do not have the means to build $800 X-overs (though I do appreciate seeing what's possible) it's just a realistic as looking at a Ferrari.....I'm a winning lottery ticket away from either becoming a reality.
Parts Express used to have a whole bunch of designs available from various sources. While you may have to examine them, some of them are vary scienced out, while others are possibly "textbook" designs, you may want to look at them, or the ones on the link Indm provided.

Russellc
 
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