AK Design Collaborative - Insignia-Class Economy Speakers (a.k.a Indignia)

[dnewma04]

Ray, I'll send forstner bits with the baffles if I don't just get them done myself first.

 

[RayW]

Took you 8 minutes to post. That was about 7 1/2 too long. I went ahead and ordered the big guy. Like I said, it's something I should have anyway.

On the through hole I'd be tempted to drill it too small and then use a trimmer bit (I have one with a 1" cut) with the PVC in place so that it matches up perfectly with the port. If I end up with them I'll try both ways and see how it turns out.

Ray

 

[dnewma04]

That is exactly what I had planned on doing myself. Ray, you are the man. Thanks for bailing me out.

 

[TerryO]

He does not right now, but he could easily order a 1 7/8" Forstner bit for the drill press and git 'r done.

I have the "big" Jasper circle jig for the router which only goes down to 2 1/4". When I bought it, it was "the Jasper circle jig" and that's all there was. Anyway, I'll order up the bit, which I should probably have anyway and I'm pretty sure I can do it with that one and a 1 1/2" spade bit (which I do have) for the through hole.

Note: I didn't need this for mine as I used a through hole, sanded the port flush on the front, and used a roundover bit to smooth things up and add the port flare.

Ray

Ray,

I've had good luck in the past just cutting out (with a sabre saw) a small "collar" a little bigger that the OD of the vent (being poor, I just use schedule 40 PCV pipe) that I then epoxy to the back of the baffle and then, when it starts to set, epoxy in the precut pipe, having already figured in the thickness of the baffle. I go back later and use a spade bit to drill a large enough hole to get a flush cutting trim bit in and use it to route out to the exact ID of the vent. You can then use a roundover bit if you've calculated a bit extra length to compensate for the flare. Of course, this is really for painted cabinets, although it can be used with some modification for Veneer.

Late Edit: I see that Ray has already posted while I slooowly typed.

Best Regards,
TerryO

 

[RayW]

That's a good idea to make things easy, Terry. I'd probably use something like a PVC union for the collar. Glue it in the right place and the PVC port will fit perfectly. Then drill out the middle and use the flush trim bit.

I do like the elegance of using a Forstner bit to drill the OD in the back of the baffle so it fits right into the wood. We'll see how it works out.

Ray

 

[TerryO]

That's a good idea to make things easy, Terry. I'd probably use something like a PVC union for the collar. Glue it in the right place and the PVC port will fit perfectly. Then drill out the middle and use the flush trim bit.

I do like the elegance of using a Forstner bit to drill the OD in the back of the baffle so it fits right into the wood. We'll see how it works out.

Ray

Santa brought me a whole set of Forstner bits for Christmas, but I haven't had a chance to use them yet, but that sounds like an easier method if the tools are available.

Best Regards,
TerryO

 

[Robie]

Dave,

While they are not my baffles, I'm sure those waiting would agree that an old adage is applicable here. "Don't sweat the small stuff (and baffles are definitely small stuff)."

Get well soon.

 

[shrinkboy]

what robie said

 

[webbb]

I do like the elegance of using a Forstner bit to drill the OD in the back of the baffle so it fits right into the wood. We'll see how it works out.

Ray

You will have drilled an 1/8 inch pilot hole first to align the centers... Drill the big one from the back first, and make sure you line up nice on the pilot hole. Then do the through hole from front. Again be careful. Maybe it moved when we clamped it... but I have one that just barely makes it - through hole lines up at the edge of the big hole instead of centered. Also,the 1-7/8 is a very tight fit on the PVC, at least on my black sch.40 - best to round the edge with a file or sandpaper, then whack it in with a rubber mallet. It does not come out without a lot of effort. A small ring of the pipe, maybe 1 inch or so, then a 22.5 degree angle, then the rest of the port pipe just slides together and fits behind the tweeter.

The second baffle came out great. Since they are behind the grille, and painted black, it is not so bad an oopsie. The picture attached may show the step that I got from the alignment problem. It is hard to see now that I painted it black - and I am not even sure if this is the one with the problem (I am not with the speakers at the moment.) The Forstner bits do cut nice smooth holes.

 

[Russellc]

Ok, here is a brief history of the last couple of months, and some reasons behind my tardiness. In november, I ordered two sets of baffles and promptly destroyed both by not double checking my measurements on the fixture I made. Amateurish mistake number one. So, rather thn having two sets ready to go, I just threw away a good chunk of money on a stupid mistake.

About that time, we found out that Liberty would require surgery on a small cyst she developed on her face. That essentially took out 2-3 weeks of available time and the holidays hit. During the holidays, we learned that my wife might need reconstructive foot surgery and she needed to stay off of her feet for a while to see if some issues would correct themselves or if the surgery would need to be setup. Shortly after the holidays, I noticed a decent size bump on my torso and was diagnosed with an umbilical hernia. That isn't such a problem but I couldn't get that surgery done if Christie was going to have to have her surgery. Lastly, my switch for my router broke, I ordered one from a parts supplier and received the wrong one so I pulled the router apart and effectively removed the switch from the circuit, there is a hand trigger that would keep it "safe" to use while waiting for the correct switch.

Finally, we found out that Christie doesn't need reconstructive foot surgery (yay!) and I had my umbilical hernia surgery done last week.

Tonight, when downstairs I didn't see that my circle cutting jig was scratching the baffles and I ruined 3 more, or at least marred them enough that I would never send them out that way. I am ridiculously embarassed and as stupid as I feel right now, I am even more angry at myself for wasting more money as I'll have to reorder some of these baffles until i have time to fix the repairs.

I offer this not as an excuse my tardiness, but just an explanation of the cluster that things have been like recently. I am sorry for being late, I will have two sets of baffles going to Ray (if Ray has the provisions to make a 1.5" through hole with a 1.875" 1/2" deep bore from the back side) on Wednesday to cut the port holes for Zilch and WiredBecker.

The other baffles have just been ordered and I will work on them Thursday providing they arrive by then and Saturday if I can't complete them (right now, i am working on things as I feel decent but obviously I couldn't concentrate enough to do them right.

All is not a total loss, when the weather breaks, I'll get these damaged ones sanded out in case there is a next round of this, although, at this point, I don't expect to be offering to do the routing again because of the gross incompetence I have shown.

Sorry again and thanks for the overwhelming patience.

Dave

Hopefully mine are in there somewhere also! I've got two more crossover projects to complete, then I'll be bored!

Russellc

 

[Russellc]

russellc

 

[dnewma04]

Replacement baffles have arrived.
Router is working.
Incision is feeling good.
Liberty is feeling good.
No more pain killers required.
Getting out early from work.

Things are looking up.

 

[Robie]

Great news, Dave ^.

I'm hosting a Chicago-Area Get Together on Sat. Feb. 28th. While it sounds as if many speakers will be attending (along with their AK owners), I hope to impose the InDignias on all attendees.

I will report the reviews, reactions and results ASAP.

 

[Zilch]

I will report the reviews, reactions and results ASAP.

I certainly look forward to reading your report.

I'm hoping Ken Kantor will write up a mini-review once he listens to (and maybe measures) my pair.... :thmbsp:

 

[Robie]

I'm hoping Ken Kantor will write up a mini-review once he listens to (and maybe measures) my pair.... :thmbsp:

Cool. Can't wait to hear/read Mr. Kantor's opinion. I've always enjoyed his insight.

 

[Russellc]

Great news, Dave ^.

I'm hosting a Chicago-Area Get Together on Sat. Feb. 28th. While it sounds as if many speakers will be attending (along with their AK owners), I hope to impose the InDignias on all attendees.

I will report the reviews, reactions and results ASAP.

I will be taking my set to Jaymana's mini fest in June. I dont think anyone else in our crew is doing Indignias, so it should be a first see for many. We do have a couple of E'wavers I know of.:thmbsp:

With these "showings" of Indignia, and if Ken gives a review,
the second group buy should be huge!

Similarly, I will be reporting reactions to Indignia as well.

Russellc

 

[beans]

We're finished with #9 and will finish #10 this weekend. Where do I get black screws? Couldn't find any at HD or at Blowe's.

SORRY... LOWE'S LOWE'S LOWE'S
I forgot how some have their sensibilities offended by that sort of thing.

 

[pocketchange]

I got's to ask, in lieu of this from a spare time prospective project, have you ever looked at the little ONIX X-Ls Speaker? It's cheap as dirt, designed by some good people and built to jaw dropping standards ;>) pc

 

[Zilch]

Cool. Can't wait to hear/read Mr. Kantor's opinion. I've always enjoyed his insight.

Good or bad, I expect he'll speak the truth. :thmbsp:

We're finished with #9 and will finish #10 this weekend. Where do I get black screws? Couldn't find any at HD or at Blowe's.

Gun bluing will make them black, I forget the brand.

Alternatively, stick them in a piece of cardboard and spray 'em black.

[You're gonna miss your asterisk. ]

I got's to ask, in lieu of this from a spare time prospective project, have you ever looked at the little ONIX X-Ls Speaker? It's cheap as dirt, designed by some good people and built to jaw dropping standards ;>) pc

We've looked at Insignia, Presidian, and Minimus 7 so far, and Indignias are simply on another performance level. :yes:

 

[Russellc]

Starting to get excited about the prospect of getting these playing. when finished I imagine Rybeam will drop by for a listen, or I will haul them over to him to do so. Got to get back to CC E'wave crossovers and finish them up, sounds like Dave is getting healed and caught up a little since the landslide of life decided to dump on him. Go Dave! Great project, any further word if this will become a PE project? Really should be, based on all the positive reviews from you guys who are finished with the build.

cheers,

Russellc