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First Time Crossover Build

jaymanaa

jaymanaa

RIP 1961-2018
Well, I got my parts today for my DIY crossovers :scratch2: I gotta tell you guys, I feel a little silly. I took the parts order that Paul C. suggested and set down with the old PE book. I figured I'd upgrade a couple things, because I have the sickness. I was expecting freekin capacitors, not beer cans. This proves once and for all that I'm an idiot :yes: I'm planning on building both channels on one Lexan and poplar chassis, which apparently will be larger than my 2.5 watt amps. Heck, I may be able to run my big amp (5 watts per) on these dudes. If you guys could see the little piece of Lexan I was planning to use, you would understand my utter shock and dismay. Anyhow, I guess it's all part of the learning curve, which is a little longer arc for some of us. I will start the layout process tonight on some cardboard. :yes: If anyone has ANY guidance or suggestions (or if you just want to poke fun) please chime in. I have enclosed a pic of the hideously oversized components for your viewing pleasure. In closing, I would add that this is in no way Paul's fault, as I'm sure the actual parts he proposed would have been of a more normal size, Jay :D
 
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I did sketch it out on paper before I set anything in place. Even then I just secured everything with wire ties. I may go back and glue it all down at some point.

Take care,

Ed
 
(Jay's wife throughout this entire project)

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"Jay, you've GOT to be kidding me!"


Hahahahaa.... Jay's already got speakers "as big as a Subaru and costs as much! (He'll) never have to trade (them) in. (They are) gonna be with (him) for the rest of (his) life. And when (he) die(s), they can bury (him) in (them)!" (paraphrased from the stereo store scene in Ruthless People)

... and he's complaining about the size of the crossover???

I suggested the 1600 hz horn, but would you listen to me? Noooo! You got those great big 500 hz Voice of the Theatre horns! Seriously, Jay, those are PERFECT!

You know, you could have gotten electrolytics for the shunt caps in the woofer section. They would have been 10% of the size. :yes:

On the other hand, those should really impress the golden ears guys. :D

The caps, you can glue those with E6000 or Aleene's 7800 (craft store items).
 

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And my 5 watt per channel amp weighs 42 pounds :scratch2: It would seem as though I have size issues :scratch2:
 
Jay, I can't thank you enough for doing all this right before I get started - I should send you a tutor's fee! :D

At least I only have to build ONE of each for my project... :smoke:

And yes, the film/foil caps can get BIG. One of those looks at least as big as a 4800uf I've got for an amp project. I've handled motor start capacitors for submersible pumps, some of those things are thermos sized. (It's really fun to wait for someone to reach for one, then goose them in the ribs while you go "ZZZZT". Just make sure they're not holding a screwdriver. Ask Fotno.)

Are you going to mount the crossovers in the speaker cabs, external, or at the amp position?
 
I think it will sit on a shelf somewhere between the speakers (maybe behind the amp). Here is what I came up with for a layout (single chassis for both channels). This is do-able on a 12x12 surface. I'm wondering about magnetic fields produced by the inductors? The two small ones are pretty close to each other. If anyone would care to critique this layout, it would be appreciated. I'm pretty much flying blind, Jay
 
Perhaps you can separate them by turning that layout "inside out", repositioning those coils to the outside? And further, reversing one side top for bottom. Your coils would be on the corners, around the outside edge, all well separated from each other.
 
Paul C said:
Perhaps you can separate them by turning that layout "inside out", repositioning those coils to the outside? And further, reversing one side top for bottom. Your coils would be on the corners, around the outside edge, all well separated from each other.
Click to expand...
Very nice, Paul. A little Yin and Yang for Jay's crossover board :thmbsp: That's the kind of build I can get behind... good karma influences there, too. :music:
 
Good lord Man! That's already starting to look impressive!

So, just for my own education, you're going to build the crossovers for both speakers on one board that will live outside the cabinets?

Take care,

Ed
 
Yep, This is for a horn system and I want it to be accessible for tweeking. It will pretty much be like another component. I'll move things around and post another pic. Thanks, Jay
 
lndm said:
Hi Jay,
Have you seen SET12's crossovers?
http://audiokarma.org/forums/showpost.php?p=832145&postcount=22
Click to expand...

Thanks Indm,

Jaymanaa, Where did you get those very pretty green inductors and what brand are they?

And yes if your really interested in voice various brands it would be a good idea to not glue mine are fastened by velcro and are connected using Radio Shack gold plated brass terminal connectors that have hex allen screws so I can disconnect or connect in a matter of minutes I haven't tried any different brands yet but I can tell you that these Hovlands took for ever to break in and I am still using very small MIT polystyrene caps as bypasses you will notice a sense of focus that is not possible with the network mounted in the enclosure I had mine sitting on top of my Forte's and I can tell you even that is audiable they are now on the floor! My Fortes are all rewired with Audio Quest Indigo and Midnight for the woofer I use Audio Quest clear from my amps and I bought all of the wire for the bargin price of less then 100$ so look around if you want to use performance wire you might be able to buy it for penny's on the dollar! I installed the autoformer in the black case to make the crossover a little more appealing to look at I can't remember but it might have been a Radio shack box if not I got it from Hammond it is plastic as is the other box's with the terminal connectors the project has brought me some of the most satisfying listening in decades the Forte is a real sleeper and with mods like these they will perform as though you spent thousands!

So best of luck on your project!

SET12
stockcrossovervsmodifiedju0.jpg
 
Now that is a crossover :yes: :banana: Man, I love big audio stuff. It's just cool as heck to look at. I think I have devised a way of mounting the components which will allow some flexibility. I just got back from a Home-Desperate run (gosh I hate that place) and have enough stuff to make a start. I'll report back with either a progress, or setback report. :D
 
lndm said:
Hi Jay,
Have you seen SET12's crossovers?
http://audiokarma.org/forums/showpost.php?p=832145&postcount=22
Click to expand...


I rarely use the much-overworked adjective "awesome", but as crossovers go, those are truly awesome-looking! And I thought the crossovers in my IRS IIIs were impressive when I saw them... :sigh:

Darn you guys! :nono: Now you have me wanting to run out and get some huge black caps and components and thick gleaming copper wires for coils and some giant old-style variable tuning capacitors from the early days of radio (replated in gold, if it wouldn't ruin 'em) and then design and buld a massive, hulking component-sized variable crossover creation atop a slab of granite and wood, with a transparent case over the whole... :scratch2: :D
 
jaymanaa said:
Now that is a crossover :yes: :banana: Man, I love big audio stuff. It's just cool as heck to look at. I think I have devised a way of mounting the components which will allow some flexibility. I just got back from a Home-Desperate run (gosh I hate that place) and have enough stuff to make a start. I'll report back with either a progress, or setback report. :D
Click to expand...

Thanks, Thats good its got you thinking which is how I got started after hearing a friends DIY ALK LaScala crossover that was done outboard on plexiglass it was a tremendous improvement and for the first time I heard real bass from a LaScala that evidently has a midrange peak that ALK was able to design a crossover to eliminate the issue this inspired me to do my crossovers but I had no issues with its design so mine are a direct copy of the stock crossovers only higher performance parts BTW my inductors are 8ga the largest manufactured ones offered comerically at the time from North Creek Music they are now out of the DIY business unfortunately.

SET12
 
OK, about 4hours into this deal, and thought I'd post an update. I marked out the Lexan for everything, and started whittling on the poplar. Bear in mind that I am a pipefitter by trade, so my woodworking is learn by making kindling. :D The sum weight of the parts is somewhat substantial, so I cut a little ledge in the wood, that the lexan will rest in. Had this been an AL plate amp chassis, I would have just used blocks underneath, but with the weight and the fact that you can see through, I did this instead. There will most likely be additional cross bracing underneath, which is why I decided to get the chassis issues completely lined out prior to any wiring. The one pic shows how I used the table saw to cut the groove. It was like using a router in the fact that I had to make several passes to get a clean straight line. Now to cut the corners, and hope it all fits together.
 
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