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Blog series by stefang updated 12-18-2019 04:54 PM 4 parts 3962 reads 61 comments total

Part 1: First Steps

12-15-2019 11:59 AM by stefang | 24 comments »

My son was searching for unusual speakers on the web and he found a nautilus seashell style that he liked similar to this one. Most were molded with some type of plastic. The one shown below was 3D printed except for one which was made of plywood. Here is the only plywood on the net as far as I know. there was no construction information available for this one, so I had to figure out how to make it myself. It was made by James Meacham at this website. My son asked me if I c...

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Part 2: Time for the rubber to hit the road

12-16-2019 01:18 PM by stefang | 11 comments »

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 ...

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Part 3: Cutting the Wedges to fit the pattern

12-17-2019 12:58 PM by stefang | 12 comments »

Here is a teaser so you can get an idea of the size of the horns. Keep in mind that there will be trumpet like ends attached to the horns. I will be making these end pieces with plywood rings similar to segmented turnings and turn them on my lathe. Once the individual segments were cut, they needed to be cut into wedges so that they would form the curl in the horns. The outside thickness (or top) of the segment squares would remain the same. The inside edge, (or bottom) of each square...

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Part 4: Marking and more Cutting

12-18-2019 04:54 PM by stefang | 14 comments »

This is one of the two 90% finished horns being made. Last time the square segments were marked out and cut into wedges according to the pattern. Now it’s time to mark out for cutting in the scroll saw. This marking was for an earlier failed rendition and the inside diameters were enlarged for the final horns. After cutting the the segment round and hollow now a centerline on the thick top edge and the same on the bottom thin edge was marked out. This is to aid the corr...

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