HORN SPEAKERS #2: Time for the rubber to hit the road

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Blog entry by stefang posted 12-16-2019 01:18 PM 879 reads 1 time favorited 11 comments Add to Favorites Watch
« Part 1: First Steps Part 2 of HORN SPEAKERS series Part 3: Cutting the Wedges to fit the pattern »

After figuring out that I needed about 56 square pieces of 3/4” plywood all cut to different sizes I marked them out on a baltic birch platter. I had some half of full size platters in the right dimension. Unfortunately I didn’t have room to cut the marked out strips on the table saw so I had to use my circle saw instead. These formed a 47” long thin wedge shaped strip with the individually marked pieces becoming smaller towards the end.

This is how I had to cut the strips with the platter on top of my combi machine:

Critical to these strips was that the outboard edge was perfectly straight and the inboard edge was perfectly parallel with the outside edge. The dimensions of each square were determined by taking measurements directly from the pattern. You might notice that the same nos. appear on the strip together. This is because I am marking out the pieces for two horns at once.

The individual pieces for each strip were marked off and numbered to help keep track of their position on the pattern. The width of each piece was based on it’s length to create a square. I cut each strip a little wider than necessary so I could could cut to final width on my tablesaw. This was to make sure the cut was nice and straight. The outside edges that I cut with my circle saw were routed straight prior to marking out.

I sawed the strips into squares using my miter saw.

The individual pieces lined up then the pieces for 2 horns were boxed to prevent losing them.

Problems encountered with the marking and cutting were numerous. Keeping in mind that what I have shown you here is after doing this 4 times incorrectly. Here is a list of what I did wrong on those failed operations.

  1. I used my circle saw exclusively for cutting the strips lengthwise resulting in less that straight lines that made the eventual squares not so square and also making them a slightly smaller width after sanding to straighten edges. They weren’t out by much, but as I found out underway, they have to be almost perfect to fit the pattern. If they don’t the result will not be the desired horn!
  2. When cutting the individual pieces on my miter saw I found that I had not allowed enough space between each square resulting in the cut being wider and making the pieces a bit shorter than intended. Better to have a little too much space and trim them as necessary!

I take full credit for not being focussed enough on marking out and cutting accuracy and being generally complacent. This was only the first cutting process and I resolved those problems after my first failure. However, there are are other operations that failed on subsequent attempts and it seemed that I was only able to solve one problem per iteration. So I hope you will stay with me and learn more silly stuff from the next blog in this series! The next steps will cover the marking and cutting of the wedges to create the curve of the horn as seen in the first photo.

Thanks for reading and please let me know if my explanations are not clear enough to be understandable.

-- Mike, an American living in Norway.

11 comments so far

View a1Jim's profile


118163 posts in 4743 days

#1 posted 12-16-2019 03:10 PM

I’m still in awe of this project , as for me I couldn’t even imagine where to start , I see no reason for you to apologize for not being focused, this project is going to take more trial and error to complete.


View ocean's profile


232 posts in 1999 days

#2 posted 12-16-2019 03:24 PM

Waiting for the next installment. Very detailed and will have to read it all over a few times to get it set in my head!

-- Bob, FL Keys

View shipwright's profile


8734 posts in 3963 days

#3 posted 12-16-2019 03:38 PM

Sounds like a good time Mike.
There are two ways to do this. One is to spend all your time planning until you know you have it right.
The other is the way WE do it! :-)

-- Paul M ..............the early bird may get the worm but it’s the second mouse that gets the cheese!

View MrWolfe's profile


1654 posts in 1289 days

#4 posted 12-16-2019 04:09 PM

Thank you Stefang,
Great blog for a TERRIFIC project.
Thanks for the detailed descriptions and photos of BOTH your successes and failures.
I really enjoy this type of blog, especially this one.

View theoldfart's profile


12757 posts in 3617 days

#5 posted 12-16-2019 04:26 PM

Explanations are clearer than most Mike, think of it as on the job training.

I like your dedication to getting it right.

-- "With every tool obtained, there is another that is needed" DonW ( Kevin )

View Redoak49's profile


5328 posts in 3154 days

#6 posted 12-16-2019 05:24 PM

Great job with blog.

View sras's profile


6261 posts in 4295 days

#7 posted 12-16-2019 11:10 PM

A little trial and error helps a lot. I can’t imagine how anyone could just think their way through to an error free build on something like this!

-- Steve - Impatience is Expensive

View Joe Lyddon's profile

Joe Lyddon

10963 posts in 5218 days

#8 posted 12-17-2019 01:07 AM

Stefang, I admire the way you are putting your imagination to work!

I think you will get it together…

The one thing I would be concerned about, is getting it all together, and it’s OUT of TUNE and can’t make any good quality sounds. Will it be possible for one to their lips up to the input point?

It will be good to LOOK at… maybe that’s your main objective… (?)

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: ... My Small Gallery:

View lightweightladylefty's profile


3658 posts in 4878 days

#9 posted 12-17-2019 06:04 AM


This is really incredible! That $60,000 price tag just keeps looking cheaper all the time.


-- “Those who would give up essential Liberty, to purchase a little temporary Safety, deserve neither Liberty nor Safety.” Benjamin Franklin -- Jesus is the ONLY reason for ANY season.

View stefang's profile


17040 posts in 4500 days

#10 posted 12-17-2019 09:42 AM

Thanks for the comment everyone

Joe I have no idea how good the sound will be. These speakers are pretty small though, and the horns are also quite small. My son is planning to mount these on his desk at work (advertising agency), and I don’t think they will be played very loud. There will also be a trumpet-like ending on the horns that I will be able to turn on my lathe. These should contribute somewhat to the sound.

-- Mike, an American living in Norway.

View mafe's profile


13204 posts in 4255 days

#11 posted 12-18-2019 07:50 PM

Love that you not give up and just keep making new versions as you go.
Best thoughts,

-- MAD F, the fanatical rhykenologist and vintage architect.

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