The speakers have begun. They are Zigmahornets, based on a design found around the internet, and reviewed here. I have all the sandeply plywood cut into strips, mitered, and rabbeted for the front, back and sides. The next part is to create the 45 degree angled front, the base, and the port. I am going to be using a pair of single driver speakers, Fostex FE103 series. More coming soon, so stand by.

Update (July 1st, 2007):
I have almost completed the assembly of the Zigmahornet basic cabinets. I’ve sealed the edges inside using silicon latex caulk, and cut the holes for the speaker drivers with my router (I had to make a custom circle jig using the baseplate). They are almost ready for wiring and the drivers, and then final finishing.

Update (July 6th, 2007):
The Zigmahornets are finished. I made a pair for Woody too, and he’s said that they sound very good. They sound fantastic for the price and effort to me, and I have them hooked up to my Sony minisystem right now to break them in while we’re away.

Update (July 17th, 2007):
The speakers have been relocated to the shop for light sanding, hole filling, and two coats of natural danish oil. I opted for this as I can always recoat later if they get dinged up, and it doesn’t alter the look too much. It also hides the imperfections and wood puttied holes better too. I removed the stuffing (poly-fill) from the lower portion of each cabinet, sealed them a bit better, and closed them up. With the broken in drivers, they should sound pretty good. Woody has tweaked his a bit more than I have and he reports that they sound very good. He painted his black (see the photo gallery).

11 thoughts on “Zigmahornets

  1. Hi – Doing a search on dipoles and found your site. Very helpful and got some other ideas here as well.

    Thanks for documenting your project.

  2. Thanks Jeff. I’ve been pleased with the performance of the Zigmahornets so far. They sound great, especially with good quality recordings, jazz, vocals, and classical music.

  3. Hi- I just buil my Zigmas. I found no indications of how much, if any, damping is needed. So far they sound very edgy, but the drivers are new.

  4. When I built my two pair, I gave one pair to a friend of mine who happens to be very good with speakers. He gave me some damping materials, and we experimented. Basically, we used some light filling throughout, and a little at the interior opening of the port at the bottom. With new drivers, they need some time to break in, so I would run a source through them for about a week straight to break them in. Music at a low volume will suffice.

    We also put some rubber diffusion matting right behind the driver (epoxied the matt in place.)

    You just have to experiment to get them the way you like them.

  5. OK. I’ll play them for a while. I mounted the backplate with screws only to be able to experiment with different damping.

  6. You mention experimenting with the damping materials but how are you able to continue to open and close the speaker enclosure? Thanks.

  7. Basically (and you can sort of see it if you review the pics) I changed the back a bit from the original design, and added a rabbet on each side of the back so it fits snugly in the enclosure. Then I just screwed the back down. Before completely sealing it with caulk and wood putty, you can experiment with different damping materials and amounts. You do get some air leakage doing this, but it gives you a good idea of how much and what to use before completely sealing it. I didn’t glue the back on so worst case you can always unscrew and remove the cover even with the caulk and wood putty seals. I’m sure one could experiment with rubber seals as well, but that would increase cost and build time.

  8. I am hoping to build a pair of these soon but can’t find the pictures you refer to. Is there a link I’m missing? Thanks.

  9. Hi Craig, enjoyed looking at your build. I am going to build a pair soon. Did you use 3/4 ply or 1/2. Hard to tell from pics. I know the plans call for 1/2. Just curious

  10. i used 1/2 plywood. it was actually sandeply. if you can get a hold of birch that would be even better. the sandeply tends to splinter a bit, so it needs to be sanded on the edges really well.

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