PR Audio,
WOW! What's your opinion on foam core and where did you buy the boards?
I believe that foam core (FC) in no way is a permanent substitute for wood (ply, mdf, etc). But, if you are not an experienced woodworker, it is a very easy material to work with, it can be cut with a razor, razor knife (X-Acto), or cutting wheel. There is also
tools and specialized cutters meant for FC work. Cheap material, so if you over-cut (smaller than correct size), you can throw it away and recut the piece. Easy material to work with, so if you under-cut (larger than needed) just take the piece, mark the new cutting line, and cut with razor. If you get gaps, hairlines, or crooked edges, fill with epoxy or bondo (same as wood). You don't have to sand, like wood. Wood glue on FC only takes 2-3 minutes to hold, and some 10 minutes for a strong bond. You can also use epoxy or hot glue to bond (many prefer hot glue).
Let's take the Planet 10 uFonken design you see (those pics are unpainted enclosures). Though I purchased the 1/2" plywood to build them, I'm not a great woodworker, so being able to make a working mock-up in some 45 minutes from start to finish is great. I was also able to see that I had cut the top and bottom panels too big, so I had to recut with the knife. Now, in my wood panel, I can adjust the measurements of the drawn top/bottom. And, if the FC speakers sound nice, I will keep them (PC nearfield use), and will use the 1/2" baboon plywood for another home or speaker project.
As for the foam core, you can buy local or online from many arts & crafts/engineerig & architecture supply stores. You can probably also find locally at signage supplies stores. Personally, I like
www.dickblick.com, though I buy it locally at a school supply store.
I came across a thread in DIY audio talking about the use of FC, people have done amazing speakers with FC. And, I remembered that a couple of years ago, at my son's school they had requested them to bring 6 pieces of flexifoam in different colors. My wife and I didn't know exactly what flexifoam was and purchased 3/16" thk. x 20" w x 30" l colored (one side) foam core boards @ $4.50 each. Well, as it turns out flexifoam is the size of letter paper, about 1/8" thk., solid colors, and a pack of 6 costs like $3.00. So, after two years in my son's bedroom closet, I found a use for those surplus sheets I had. Got plenty for more speaker projects (I see floorstanding 3" to 4" full range horns in my near future).
You can see the finished (painted) Foam Core enclosures
here.
