As you may have seen, I did the sound system for Nick Barnett’s night club a few years back. Recently he contacted me about the recording studio he was building at his home. He wanted a very high end monitor, the likes of the Genelec 1037’s but without the $25k a piece price tag, and something that would actually fit in the available space. As the system would be all active with full DSP, I contacted my friend Mark Seaton. Some of you may be familiar with him.
We came up with a plan for a high end monitor that would allow for monitoring at up to 120dB all the way down to the 10hz range. The system consists of a B&C 8″ coaxial driver with 1.4″ compression driver, a pair of TD10X’s for the midbass, and pair of custom 15″ drivers for the woofer section per side. As the room is small, and to keep things simple, all sealed enclosures are used. Power is supplied by a 3 channel SpeakerPower amplifier for the tops and a single channel amplifier for the subwoofer sections.
The first issue I faced was to come up with something unique for the cabinets. I didn’t want just an average plain flat box in the wall. I had some 3″ quarter rounds and decided to order more to use them for the cabinets. They would essentially round out of the wall 3″ then. I wanted to do solid oak inserts to really set off the cabinets and stain to match the oak floor to tie everything together.
We decided to use pocket hole screws to attach the front baffle board to the mdf quarter rounds as they would pull the seams tight. It is very difficult to clamp a quarter round without the screws in place first. We then used the clamps to pull the inside edges tight.
Next we ripped, planed, jointed and glued up the solid oak for the inserts. Nothing too fancy here. Just needed a nice flat slab to cut on the CNC.
Next we started to make the amplifier housing section that would go above the subwoofers and below the main monitors. Again the same quarter rounds are used as this will look like a continual column going up the wall.
Here we were cutting the inner baffle layers and the inner plate for the actual mounting of the amplifiers. Also at the far end is a template we used to cutout the oval shaped recess in the front baffle for the solid oak insert. We couldn’t just cut this shape on the CNC originally because there was too little material left at the edges of the piece. It had to be trimmed out after the front was attached to the quarter rounds.
Here we have glued up the sides and tops for the subwoofer cabinet. The angles cut at the top match to the back side of the quarter round and the front baffle.
This is a test fit of the baffle and quarter rounds onto the rest of the cabinet. Looks to fit well. Lets glue it up.
The subwoofer cabinet is together and so is the amplifier section. Here is a pic of the two of them stacked on top of each other as they will sit when mounted in the wall.
Now we can cutout the solid oak accents on the CNC. Using small passes and a downcut spiral bit gives a nice clean edge with no chipping.
Now the part that gets very tricky is the front baffle on the main speakers. The cabinet mounts to the section of the wall that is angled down by 22 degrees. The 8″ coax also has to be mounted so that it is towed in by 13 degrees to be at a proper angle at the listening position. Lots of angles means lots of cutting small pieces without a full 3d drawing up front. First we glued up the two layers of the front baffle.
Then once they were glued up we had to cut them to match the correct angle for the 8″ coax. We also had to cut the solid oak accent at the same place. Here you can see the initial drop in of the oak accent on the tops and also on the subwoofer cabinet.
That’s all for this update. More pics to come as the tops are finished up today and we begin the finishing process.