There were 3 boards of walnut left over from when we built the furniture for the family room. It is well aged (over 5 years) and it will help the speakers to match perfectly with the room. This was milled to the exact thickness of the A1 cherry MDF sheets. Then the components were milled with loose tenon mortises using the Festool Domino. It is an excellent joint, and far superior to the biscuit joiner. The tops and bottoms (8 each for 1 pair) were then clamped for 4 hours each under pressure to form flat panels.
The JBL's had another failure a few weeks ago and I decided it was time for them to retire after 25 years of service. I started looking at options, but I could not afford to buy a nice pair of new speakers. I looked at some used ones that were available within driving distance, but the more I looked the more I realized I could build something much nicer. I have never owned Klipsch or any other horn speaker, and I have always said it would be nice to try a high efficiency pair. While looking at used Klipsch speakers I found a guy named Bob Crites from Crites Speakers who supplies new crossovers and drivers to upgrade existing Klipsch. He also has a great design called a "Cornscala" that combines the best attributes of the Klipsch Cornwall and the Klipsch Lascala.
I started out only milling the motor board (baffle) and telling myself I would not really build a pair, I just wanted to see if I could mill the MDF pattern for the motor board. But that quickly spiraled into a full blown effort to modify Bob's original design to incorporate split cabinets and different grills. And that led me to really wanting a pair in China, so I thought I would build TWO pair.... I wanted to have the cabinets match the existing cherry furniture and in particular the coffee table. So I chose to use 3/4" MDF core cherry ply, A1 grade for the first pair. The layups were done in CutList Plus using a series of manual drawings I used to develop the design. The panels were VERY heavy, and I broke them up on the workbench prior to moving over to the table saw. I am starting the edge banding process today, and clamping the first of the tops and bottoms (total of 8 pieces per pair).
Sometimes people ask me where to learn how to do woodworking. I had to learn myself by reading online and reading books - oh - and failing a lot. My skills are only mediocre, but if you are young and can find a way to either apprentice or go to school, that is the best way. There are lots of different schools, especially in the America. The new techniques involving shaping and creating modern pieces are very interesting to me, and I think they open up lots of possibilities and unique ways to solve problems. But I also very much enjoy hand tools and the traditional ways of doing joinery and milling wood. There are not very many schools that can teach you both, but David Savage's school seems to be that type of place.
I finally updated the section of the site that describes the shop. There are lots of new pictures and pages to describe how the shop is setup and the tools I use. I have not had a chance to do a browser check yet, but I hope to get that completed before I leave China.
I made it back last night and today was spent mowing and building a pair of barn doors for the shed. I am beat and finally knocked it off for the night. There is absolutely nothing better than a Thursday night with a diet root beer while driving some wrought iron square heads.
I spent Wednesday traveling out to a Beijing suburb to visit the site of an orphanage/school being built by Children's Hope. Our friend Melody is the associate director in Beijing and she knew of my interest in woodworking, so she put me in touch with their contractor. John was kind enough to take some time to let me watch his crew and see some of their work. I will try and post some more pictures later, but it was really a very, very nice facility that was being built. I really like the hutongs because they seem so much more Chinese then the modern apartments.
Put up a tab for Projects and a quick page for my 2x12 guitar cabinet. I need to do some more work on formatting and figure out what I really am aiming for with this site, but its fun to get some pics up.