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The Blue Wonders

The Blue Wonders
Design Goals
Driver Selection
Enclosure Design
Enclosure Assembly
Crossover Design
Conclusion
Parts List
About the Designer
- Enclosure Construction & Assembly -

This enclosure was constructed in what I would call typical "pro sound" fashion. Meaning it was built from 3/4" birch plywood, with an inset front baffle. The overall dimensions are 22" wide, 16" deep, by 36" tall; the baffle is inset approximately 1-1/4". All joints are reinforced with 1-1/2" strips of plywood, which also supports the front baffle on all sides. The midrange enclosure is built from 3/4" material as well and is 6" deep. The most interesting part of the construction of this was the vinyl work. The sides, top, bottom, and rear of the cabinets are covered with black leather grain vinyl, while the front features blue vinyl that I picked up at my local fabric store. 3M Hi-Strength 90 was used to secure the vinyl, which provides very aggressive adhesion and tacks up quickly. I added one little twist to the vinyl installation on the front baffle, and that was to use groove-and-spline technique similar to what is used on screen doors. This allowed me to get the vinyl nice and tight along the edges with a clean transition between the blue and black. Black metal cabinet corners provide improved durability and simplify the vinyl installation.