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AV Series
Maple Laminated GR-Research AV-1+, AV-1, and AV-C loudspeakers
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Maple speakers installed in the maple
entertainment center. Adjustable shelves, speakers have vinyl pads
underneath with the center channel slightly angled downward. |
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The AV-1 front firing in-ceiling surrounds
tuned with polyester stuffing. The grill is a single knit polyester
cloth, the speakers are 3/4" MDF built to spec that have 3/4" MDF brackets
mounted to the house framing, and caulked to the ceiling. |
The materials used is 3/4" A-Grade Maple Laminated MDF. The
benefits of factory laminate over MDF includes: saving time and money, never
peels or forms bubbles, and a perfectly flat sanded sheet. For assembly we
chose a special lock miter system that does not need screws or brads for
strength. It will, however, call for a lot of clamps and glue.
Here we see the first step, which is to cut the panels to the
right initial size and gather all the materials. We also size up the lock
mitered pieces to insure proper fit, and make sure we have all the materials
before emailing our client a cost estimate. If there's one thing I learned
being a civil engineering cost estimator, it is to estimate higher and not than
lower. Turns out we may have one full board of solid rock maple left over, and
about a full sheet of 3/4" maple. We'll have to see if we still have the extra
material in the end though.
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The Finish is called "Good Stuff" and is an
easy to apply clear Maple finish that is resistant to alcohol and water when
dry. It costs $17 per quart, but the results are professional and the
application is quick and painless. This option was chosen instead of an $80
sand and sealer + clear coat spray on finish. Not to mention the spray on
finishes add an air tool cleaning fee plus the cost of Acetone. |
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Here you can see the
excessive clamping lengths we go through on each speaker. We also make sure
there's ample glue and we clamp it enough so it all oozes out so that the
seams are absolutely air tight. To go to even furthur lengths, we use clear
silicone caulk on the inside of the cabinets so that there are no leaks.
We use maple putty in case there were any splinters of
wood that fell off the sharp edges of the panel during assembly. However,
when the cabinet has the coats of finish applied, the putty becomes a
slightly different color than the actual maple. This is why I custom mix
acrylic paints and color match any of the touch ups so that they are
indistinguishable. Even if the mistakes are on the rear of the cabinet, we
spare no imperfections. |
| 2 roll on coats of oil based
primer is used before we paint match the AV1s to the ceiling. These will be
flush mounted in the ceiling with custom molding and single knit polyester
grill cloths.
The yellow glue is applied liberally with a brush and a
roller so that there are no gaps. |
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Here we see some quick crossover assembly. I
use a Weller WES51 soldering station set to 750 degrees and 4% silver
solder. I make sure the crossover uses the least amount of wire and I use
glue filled heat shrink tubing on exposed connections. What you see here is
a crossover I assembled very fast to test the loudspeakers out. The
assembly had to take me about a half hour for a pair though I only used
electric tape to attach it temporarily to the 1/4" hardboard. |
Soon to come...
Pictures of the finished loudspeakers fully installed, with an adjustable angle
center channel, and vibration and sound dampening.
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