Yet Another (3rd!) Way to Construct a 28" Spherical Shell...

Epoxy won't set up...it's 2-part & doesn't start setting until you combine them. It's also thin until it begins to set up (2 hours in the case of the 120-minute variety).

instead of a steel band. why not use a ratchet type web strap.

instead of a steel band. why not use a ratchet type web strap.

Excellent idea!

"Epoxy won't set up...it's 2-part & doesn't start setting until you combine them"

Correct...but I'd need a big batch all mixed up standing by; no time to keep mixing it up. But with a two hour cure time, that would be plenty of time to do the whole job.

I'll probably stick with the steel bands...just use two around the "equator". I had other issues that was preventing the slices from "closing" in a few places (I'd used screws (sticking up ~1/16" to 1/8") at the base of the assembly jig to "shim" a few of the slices that were slightly undersized in North/South pole length up/down. This was a terrible idea and the slices were hanging up on these shim screw heads. Should have either done more slices (the undersized ones were from very early builds wherein the jig I was using was not quite "perfect" yet). But I got impatient. Normally the force from one of the steel bands I'm using would have been adequate to squeeze all the slices together (and it did in the "dry run" BEFORE I added the shim screws). Good news is I can fix the few slices that are slightly out of place with plastic wood fill on the few low places and a bit more sanding. Also the few small joint gaps around the equator that did not 100% close...some of which will be cut out anyway with the driver holes, some I'll seal with either epoxy or Gorilla glue. They are only about 1/32" wide and are closed on the interior surface anyway. I know, TMI! Lessons learned from the 1st time.... I'm sure the next one will be a piece of cake! Thanks for all the helpful suggestions! Pics to follow later.- Ed

Ok....was "sick" today so really hit these....driver holes all cut and routered. Just need to do the sanding/veneering/finish and the drivers (and the handles and terminals...)... I put a couple of "blown" 8" woofers just to see what they look like...and in the last pic I set one of the new Pro 1" tweeters in place as well (try to imagine how they'll look with the teak wood veneer and not the epoxy "fixes" :

All sanded and ready for teak wood veneer. I'm stoked and will probably start this on Sunday (and hopefully be DONE with everything next weekend..). Can just make out the 32th "facets" that allow the veneering... Also, talk about strong/stiff: you can put all your weight on any of the 8" woofer cutout edges; they don't deflect at all (well at least to any amount you can see or feel...). Just can't beat the ol' arch effect for strength... I'd estimate these enclosures to be 10 to 100 times stiffer than your average "flat plate" speaker enclosure...:

looking good...

kinda reminds me of the Gilligan's island mine...

four of 32 slices veneered (these two and two on the other side)....process is working...now I know how to veneer a sphere!:

Very slick, Ed! You're gotten better with each one~

I would love to hear a set of these sphere's. Elgrau do you ever go to Carverfest?

I would love to hear a set of these sphere's. Elgrau do you ever go to Carverfest?

We've been trying to drag his ass to CF for years....

Sorry; I only fly when 100% necessary....If u knew I worked for Boeing, would you fly? jk; I only do space and military side...

Veneering going a bit slower than I anticipated (mainly due to the glue issues..). But I am getting better: also learned that doing two slices at a time is NOT the best way (even tho the band clamps go all the away around and are "there" on the other side). MUCH easier to just focus on one slice at a time and goes more than 2x as fast so you get ~the same number of slices veneered per hour anyway (adjusting the bands/veneer on one side tends to mess up the other side that u cannot see...so u just end up fighting yourself). Have 16 slices done...16 to go. Was very much hoping to FINISH the speaker this long weekend but probably won't . But most likely next weekend I will....can't wait to hear how these 8" woofered spheres sound (with the 300x2 AND my new mk-II opt 2 m1.0t!). Life is good!:

Veneering is complete with 1st coat of shellac. Drivers and handles go on tomorrow and then DONE:

Not perfect, but "good enough". Can't wait to start adding the drivers and terminals tomorrow!

how many hours so far....

Roughly 100 (including ~24 just for the stupid veneering...way too many..). I put in ~10 hours today (discounting for lunch/dinner/last minute trips to HD and Rat Shack*) and finally finished! Sounds great....even with one of eight tweeters "DOA". But WAY too tired to check tonight whether or not it's the wiring or the driver... Here are pics:

Will try the mk-II on these this week....but I can say how they sound on the 300x2 will be hard to beat....

*Thought I was fucked when I went here to get spade connectors and the teen says "what are spade connectors?". But they had them.....I had wanted to solder all the driver connectors but the tweeter connectors are "anchored" in hard plastic so cannot be heated...but the 3/16" spades lock into place so I guess they will be ok. Eight drivers so I needed 16...pack said contains 16 pieces so I thought that was lucky...until I got home and found out that the stupid fucktards had 8 male and 8 female spades in the one package. I've NEVER in my life needed both male and female plugs at the same time. You almost always need just one kind. Cuts down on their inventory (one pack instead of two to stock...) but fucks their customers since I had to buy two packs and now have 16 male spade connectors I'll most likely never use....but that's what the "new" rat shack is all about. They owe me $2.79...I'll collect some day (don't get mad...get even!).