jwc

BBAAAAMMM!!! Perfect fit. My wife has a little more love for these. These speakers don't have a back on them and there are no tweeters. That is why you can see through some parts of the fabric right now. Bob Crites is sending back my tweeters as I type. The project was fun. Now...time to build some new cabinets from scratch. By the way, I have no experience doing this kinda stuff. You can do it. jc

Now, line the two together and cut you pieces of velcro. Notice I did leave a few out. There are some on the factory that are not stapled but just stuck on. I think this is worthless. The won't stay on well, I I don't think they are needed. Put two staples in each velcro. Push very hard when stapling. If the staple doesn't go all the way in, it is easy to pull out and do again.

You will need a stapler like this cheap one from Home Depot and the 1/4 inch staples. You will also need some velcro to cut into little squares. This size staples will not go through the 3/16 masonite to the front

Here is my grill next to the factory one. The same size. However, again, my masonite is ever so slightly thicker than theirs. Mine 3/16 thick. I thought this was a good move.

This part is a little harder. Your fingers will get tired. You use the 3M 77 glue spray on the edge of the masonite the pull over the material and put on the material. The use clothes pins. I got this idea from this forum. You don't have to do this process quickly. Actually, the glue works better once it gets "tacky". Once all the pins are on, come back and "push" between the pins to make the between material stick. Let dry over night. You need to do this whole process w/o touching the front side. You don't want glue from your fingers on the front.

I cut the material to about 3/4 inch over each side. I then covered the openings with paper and tape so that my glue wouldn't spray onto them. I also used a drop cloth to keep glue off every thing else.

Again, sorry for the big pictures. The fabric I used was from Parts express. They call this thier "vintage" fabric. It came 36 inches by one yard. I got two yards. The material isn't SOFT. Not like the original Klipsch. However, I ended up liking it. It is a little tougher to work with. It is more durable and would be easy to clean if needed.

Good to hear from you. Yes I bougt the glue 3m77. Used it tonight. I like it. The fabric from Parts Express considered "vintage" is 'Ok". It is somewnat "plastic" but does have the "vintage look". This stuff is rigid. There isn't much stretching. I does look good. It is very durable and I bet it would be easy to clean. I am using a ton of clothes pins as stated before. It will set tonight. I will hopefully put in the "staples" and velcro pieces tommorow night. Then one will be done. The pictures (except the glueing process) so far are on the thread "Cornwall grills". jc

Here is my measurements of an 84' Corwall grill template. This is a correction from a previous post. Thank you Budman. jc

I whipped out the Rotozip and made the openings. I then spray painted one layer on one side with flat black. They dried overnight and I brought back into the house. They fit perfectly in the cornwall leaving about ~1/16 inch around edges. Now I just need my grill fabric to come in.

Now that I have a template, I can make many more in the future w/o having to measure. Here is a pic of the 4 x 8 foot masonite with two grills marked.

The openings were perfect. This matched up perfectly. These were the exact dimensions of my other factory grills.

Here is a piece of cardboard cut to the approprate Heigth and width. The markings are made for openings. The masonite I purchased is underneath. It was less than $10. There is enough there to make 2 pairs.

Here is my measurements of an 84' Corwall grill template. This is a correction from a previous post. Thank you Budman. jc

I am about to show a series of pictures and some measurements. Please don't criticize me for the size of the pics. I still have to put on the grill fabric. I will do that portion later this week. jc

CBR SN 8512456

The K-57 is hard to replace. Bob states he has never changed out a diaphragm on one either. I'm just bummed because I hate to spend a lot of money on a new crossover and later not be able to replace a bad K-57. My B-3 or a new B-3 won't work with a K-55 from what I understand. The K-55 is "more available" and Bob can replace diaphragms. jc

Yes, I will post my dimensions there. Gonna do the posting of the whole project once it is done. Yes, I got the 3M 77 glue spray from Parts Express. My Corns are unfinished birch with brown grills. One of the Grills has candlewax on it. The other in great shape. 1984 I think. B-3 crossover, K-77, K-57-k (I know this suks), and K-55-E. jc

Well, you guys will be mad at me. I got impatient afetr I asked about the Duracrest. I instead ordered the black "vintage" fabric from parts express. This weekend I made my grill frames with 3/16th Masonite. I painted them black yesterday. They look very good. I think as good as factory. I also made a template...so in the future...I won't need to measure. Just mark, cut and paint. The 1/8 inch masonite..I thought was too flemsy. I will post a boat load of pics once I get the project completed. Shouldn't be long. I must say, my template has different measurements than the ones chronicled in the thread "let's make a cornwall drawing". I have put my grill frames in the speaker, they are a perfect fit. jc

I don't know if this is an exact match. Don't think it is cane. However, I just ordered some for my corns. Has a vintage look. http://www.partsexpress.com/pe/showdetl.cfm?&DID=7&Partnumber=261-800 This is black. They do have other colors. jc

Back to the subject. Opinion from Georgia. I have a pair of 84' scalas and 84' corns. The scalas are definately a softer, more enjoyable sound. However, I could not listen to them w/o the addition of a sub. The bass on the corn is better, lower but I would still want more...such as a sub. The mid on the corn just can't match the scala. Love em both however. I will say the corns I have are currently under some modifications that are incomplete. I don't think however, my opinion will change. jc

Yes this part of the country, we do it right. Cornwall, crawfish and Moon Pie! Man, where's my toothpick jc

I will apologize in advance if you think this is a dumb question. I also am not trying to hijack this thread. Al, Do you have any interest in designing an ES network for the late Cornwall. Is it even possible? jc

BS My wife isn't to hip regarding the stained speaker idea. She likes the Black. She wants any addition speakers to match the La Scalas and the Glass Black McIntoch. That why I may consider "piano black". Sorry this picture is so big jc

I have corns in raw birch. I think I'm going to paint. Black laquer vs piano black. jc