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Old Dec 1, 2009, 07:15 PM   #1
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DeathKnight
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Default Sonosub Build

Figured I would share my build progress with anyone who is interested.

Parts

- sonotube (18" ID, 19" OD, cut to 36")
- 3/4" MDF
- Dayton RSS315HF-4 12" Reference HF subwoofer
- BASH 300W digital subwoofer plate amp (mounting in separate enclosure)
- 4" diameter 17" long flared port
- screws and hurricane nuts
- egg-crate foam to line the interior
- etc

Tuning frequency should be about 20Hz or so. With room gain and corner-loading I should get extension well below that. My room isn't big so I shouldn't have to worry about bottoming-out the driver as I won't have to drive it to those levels to get good output. I have the top cap pieces all cut out but they aren't glued together yet. I also have the base plate cut out but I obviously still have to attach that to the bottom cap.

On to the










I hope to have it done some time this month.
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Last edited by DeathKnight : Dec 1, 2009 at 07:20 PM.
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Old Dec 2, 2009, 10:02 PM   #2
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very impressive man, can't wait to see the end result.
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Old Dec 2, 2009, 10:31 PM   #3
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Thanks! I'm going to have to go to the local hardware store to get a few things for the base (thick dowel rod for the legs, and some hardware to make the base plate removable). Made a bit more progress today.

Foam is in (attached with hot melt glue):



Top cap glued and clamped, but still needing screws:



Port glued together. I was going to do it with PVC cement but I opened up the cement and it was a solid rubber mass So I just used 5 minute epoxy instead:



Bottom wired and foamed:

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Old Dec 3, 2009, 12:03 PM   #4
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Cool project.

Did you fabricate the end caps yourself ? If so just curious how and what you used for tools.
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Old Dec 3, 2009, 12:22 PM   #5
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Yep. Used a plunge router, couple of circle jigs (one home made and the other I purchased), 1/4" straight-cut bit and then a round-over bit to finish the edge on the caps and baseplate.
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HT: Vizio E48-C2 48" LED Backlit LCD TV | Onkyo TX-SR605 A/V receiver | JBL EC35 center | 2 JBL E30's (fronts, bi-amped) | 2 JBL N24II's (rears) | Homemade Sonosub w/Dayton 12" driver (extension to 14Hz), BASH 300w amp | Panasonic DMP-BD35 Blu-ray player | Toshiba HD-A2 HD DVD player | Xbox One S
Camera Gear: Nikon D7000 DSLR | Nikon 16-85mm F3.5-5.6 VR | Nikon 50mm F1.8 G | Sigma 105mm F2.8 EX DG Macro | Slik Pro 700DX tripod legs with Cullmann Magnesit 35Nm ballhead
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Old Dec 3, 2009, 01:09 PM   #6
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Having the tools is half the battle. I'll have to see about getting a cicle jig for my router. I have quite a few bits though, they are pretty expensive for descent ones.

Working with wood is rewarding. What are you going to do with the AMP ? Build a seperate box... but where would you put it where it'll look semi descent professional ? Using a better wood to finish for it ? Pine / Oak or some other ?
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Old Dec 3, 2009, 03:08 PM   #7
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Cool stuff! and nice work so far.

I have a Parts Express sub kit, the C1500K. 15" Dayton Classic 4 Ohm, 240W Sub Amp. I can shake stuff off the walls in my living room. A decent 12" sub would have been plenty, but I went for a more budget-priced model. And, there's the wow factor with the 15" driver. All my friends are jealous.

Looking forward to your progress.

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Old Dec 3, 2009, 03:32 PM   #8
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Quote:
Originally Posted by traitoR View Post
Working with wood is rewarding. What are you going to do with the AMP ? Build a seperate box... but where would you put it where it'll look semi descent professional ? Using a better wood to finish for it ? Pine / Oak or some other ?
Haven't really decided yet. It's going to be behind my TV stand though (out of sight) so I don't think it's going to be fancy. First I have to test out the amp with the sub to see if everything jives then I'll build a little enclosure.
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Old Dec 4, 2009, 07:56 AM   #9
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very very cool

i remember back in the 80s we used to make bass buckets. we would take 5 gallon buckets and fill them with foam and drop a 10" on the top
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Old Dec 5, 2009, 03:11 PM   #10
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Looks nice. Are you logging the number of hours you are spending on this? I am curious how big of a job this ended up being for you.
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Old Dec 5, 2009, 04:27 PM   #11
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Nah, I haven't been keeping track really. If I had to guess I'm probably at 15-20 hours so far with just the build (on and off). Just finished the entire base assembly.

Screws for the legs:



Screw waiting for leg:



All legs screwed on:



Test fit (baby's solid!):

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HT: Vizio E48-C2 48" LED Backlit LCD TV | Onkyo TX-SR605 A/V receiver | JBL EC35 center | 2 JBL E30's (fronts, bi-amped) | 2 JBL N24II's (rears) | Homemade Sonosub w/Dayton 12" driver (extension to 14Hz), BASH 300w amp | Panasonic DMP-BD35 Blu-ray player | Toshiba HD-A2 HD DVD player | Xbox One S
Camera Gear: Nikon D7000 DSLR | Nikon 16-85mm F3.5-5.6 VR | Nikon 50mm F1.8 G | Sigma 105mm F2.8 EX DG Macro | Slik Pro 700DX tripod legs with Cullmann Magnesit 35Nm ballhead
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Old Dec 5, 2009, 08:57 PM   #12
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It's assembled I'm going to let the glue dry overnight and try it out tomorrow.







[edit] I will be covering the tube in some kind of carpeting.
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HT: Vizio E48-C2 48" LED Backlit LCD TV | Onkyo TX-SR605 A/V receiver | JBL EC35 center | 2 JBL E30's (fronts, bi-amped) | 2 JBL N24II's (rears) | Homemade Sonosub w/Dayton 12" driver (extension to 14Hz), BASH 300w amp | Panasonic DMP-BD35 Blu-ray player | Toshiba HD-A2 HD DVD player | Xbox One S
Camera Gear: Nikon D7000 DSLR | Nikon 16-85mm F3.5-5.6 VR | Nikon 50mm F1.8 G | Sigma 105mm F2.8 EX DG Macro | Slik Pro 700DX tripod legs with Cullmann Magnesit 35Nm ballhead

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Old Dec 5, 2009, 10:18 PM   #13
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Got antsy and hooked it up already. It works! It's not in my room at the moment though. It's across the hallway in the spare room where I was building it. I just ran the LFE output over to that room. Fired up the test tone generator and started at 40Hz and went down from there. Last frequency I tried was 15Hz and I was getting decent output. I put a newspaper over the port and it was flapping like mad. Once I get it in my room in the sweet spot it should be pretty sick
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HT: Vizio E48-C2 48" LED Backlit LCD TV | Onkyo TX-SR605 A/V receiver | JBL EC35 center | 2 JBL E30's (fronts, bi-amped) | 2 JBL N24II's (rears) | Homemade Sonosub w/Dayton 12" driver (extension to 14Hz), BASH 300w amp | Panasonic DMP-BD35 Blu-ray player | Toshiba HD-A2 HD DVD player | Xbox One S
Camera Gear: Nikon D7000 DSLR | Nikon 16-85mm F3.5-5.6 VR | Nikon 50mm F1.8 G | Sigma 105mm F2.8 EX DG Macro | Slik Pro 700DX tripod legs with Cullmann Magnesit 35Nm ballhead
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Old Dec 5, 2009, 11:31 PM   #14
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Got it moved into my room. This thing blows the socks off my old sub. Still just trying it with test tones at the moment. At 15Hz there's an intense pressure at my listening position. Output is still good at 14Hz then it drops way off. Have to calibrate it then I'll be in business. Can't wait to try out some movies!
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HT: Vizio E48-C2 48" LED Backlit LCD TV | Onkyo TX-SR605 A/V receiver | JBL EC35 center | 2 JBL E30's (fronts, bi-amped) | 2 JBL N24II's (rears) | Homemade Sonosub w/Dayton 12" driver (extension to 14Hz), BASH 300w amp | Panasonic DMP-BD35 Blu-ray player | Toshiba HD-A2 HD DVD player | Xbox One S
Camera Gear: Nikon D7000 DSLR | Nikon 16-85mm F3.5-5.6 VR | Nikon 50mm F1.8 G | Sigma 105mm F2.8 EX DG Macro | Slik Pro 700DX tripod legs with Cullmann Magnesit 35Nm ballhead
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Old Dec 6, 2009, 01:00 PM   #15
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Sweet! Is there some kind of forumla for the distance from the woofer cone to the next boundary to determine how long the legs ned to be? Or, another way to put it: is boundary loading the cone off the bottom plate part of the design goal? Kinda reminds me of a Bazooka design element.

Just wun'ering.
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Old Dec 6, 2009, 01:25 PM   #16
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Quote:
Originally Posted by Dr. Zhivago View Post
Sweet! Is there some kind of forumla for the distance from the woofer cone to the next boundary to determine how long the legs ned to be? Or, another way to put it: is boundary loading the cone off the bottom plate part of the design goal? Kinda reminds me of a Bazooka design element.

Just wun'ering.

I found this Sonosub calculator online.

http://www.subwoofer-builder.com/sonosub.htm
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Old Dec 6, 2009, 01:38 PM   #17
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Kewl traitoR! I figured, or at least hoped, that distance was taken into account using some math.
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