Arash

I'm still looking for K402 details. I couldn't buy a pair from US after a year of communication with Panacea Engineering so I just gave it up. Recently I found a good way to cut plywood or MDF or any other material with a CNC milliong machine so build horns. Now I can build K402 with any material needed. I think a BB plywood K402 will look fantastic. I'm talking about 0.02mm of accuracy on the milling machine. if there is anyone who has K402 at hand and can take it to a 3D scanning office, I will pay for the scanning. I really want to hear how it sounds on top of a Jamboree

one of the tapping screw treads broke in a hole of this part so we decided to throw it away and mill a new one. it was a symmetrical part and we could sweep it 180 degree and drill the holes on the other side but we just decides to build a new one and it's gonna be a one-time-built machine: and the new one we milled this time no Iron but 7075 Aluminum: and we just put togheter this jigsaw puzzle to see how it looks like after painting. we didn't paint machines surfaces so we will always remember how accurate it was built! a machined surface speaks very loud to a machinist: this week the machine will be assembled. we are gonna work on the PLC and HMI and electric parts next week. this knitter lady should be working about ten days from now. I hope so...

you are completely missing the point bro! a folded horn is a folded horn so no wonder that VIttora reminisces La Scala or Belle. it's about a guy who collected all the data from "Klipsch community" and concocted a commercial products and never mentioned anything about "Klipsch community" in his interview but also advertised in his website that "I grew up with Klipsch speakers and now I've now grown up to appreciate higher sound quality...". It's totally stepping on PWK's head to go up. I also can recall that Mr Volti once claimed he had the right to build and sell ALK crossover network just because he had used a base board with a different color than what ALK was using in that time! funny as hell

yes sure! sometimes you need to hold the piece with one hand and the welding torch with another hand and close your eyes for a gentle connection to hold the piece in place. you don't have to look at the ark directly it's so harmful to the ye

Audiophiles are Audiophiles! We are Klipschophiles! Who cares about those people that tend to spend all their money on speakers with small and inefficient drivers with restricted dynamic range? who can impose his metrology to people to measure which sound is better? sound should be admired by the listener so it's a subjective matter. To me a La Scala sounds better that those mega dollar speakers out there

and we painted the structure: and other parts: wheels installed:

and the feedscrew for tailstock position adjustment: the a 2HP electromotor:

It was time to weld the feet. this CO2 welding machines are great: We also bought some other parts. Pneumatic jack for the tailstock: A new thicker ballscrew and it's nut: and ballscrew nut and it's journal bearing:

We did some other parts and put everything together to see how it works. the linear bearing works flawlessly: and we added tailstock holder:

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very good way to wind coils. he sure knows what he does. but you know what winding perfect coils is all about control. if you feed the wire by hands you can't keep the wire tension steady so there is always a lot of possibility that wire will slip so it will be place in elsewhere than it's right position in the bobbin. when you control everything the wire has no way other than being placed precisely among previous turns. will result in a gapless coil. thanks bro for your promotion actually that's a Bachi Winder machine. Actually Bachi machine is the best thing we ever found on the planet. it's totally the best winding machine a coil and inductor manufacturer can thing about. but it costs about $38K and would end up something about $80K if we wanted to buy it from Iran. that's right. Oh thanks dude! Thanks George, Yes actually it's a lathe machine with a computer controlled wire feeding mechanism. for control system I'm gonna use a PLC. the PLC will have a HMI (Human Machine Interface) which is a 7" touchscreen display (you see it on the Bachi in the video at post #1). this is what a HMI looks like: Yes there will be an encoder for counting spindle turns. About braking. the main motor which is a 3-phase three horse power motor has an electrical control brake. the PLC will take of brake automatically. the motor itself is not variable (I think you mean a variable motor by "vector motor"?) I hope I'm not in a language barrier about vector motor. as I said the motor itself is not variable but we will have an inverter that controls motor speed. the PLC also takes care of inverter as well.

proving parts of a machine is a very entertaining! it's like a jigsaw puzzle as you put it together you see the result of countless of hours working in the final image

ballscrew tail ball-brearing bracket which will be placed at the right end of the machine:

thanks bro yes actually we need a lot of coils. Iran is #12 biggest producer of copper in the world so why not. we have copper wire 99.999% purity so we can build inductors here and save a lot. to be honest designing and building this machine is a little bit a long time personal game and we can also save a lot of money so why not!

the main post gate of the machine was milled with high accuracy:

we milled the feeder arm: machining this part was a really challenge. we have to position it like this: and it turned out perfect as we expected:

we built spindle bracket. it's a huge piece and far more tougher than adequate: and complete spindle: and after ball-bearings installation:

we bought some parts. 3-jaw turning chuck: linear bearings: spindle ball-bearings:

after some cutting and welding of main chassis: we welded some 10mm strips on the chassis so it is ready for machining:

Project budget was estimated between 5 to 6 thousand dollars. the machine has a 3HP motor and a heavy duty spindle with a 3-jaw turning chuck. we design everything more than adequate strong to make sure we can build coils down to AWG#8 thickness. using a turning chuck will make us able to use any mechanism needed to wind coreless inductor and inductors with bobbin and also transformers. air core inductors (without any bobbin) are tricky to wind as the coil won't slip right off the core very easily. We will design some kind of mechanism that lets the coil slip off after winding. this will be done after the main part of the machine is built. the machine will have a dedicated PLC and touchscreen HMI for functions. the motor has a electrical break so the PLC can freeze the spindle as fast as possible so the coil won't get loose. wire feeder arm will have a linear bearing and ballscrew with a 180-steps stepper motor. this will make the machine able so precise to wind wires are thin as AWG#38 (0.1 mm Ø). we may never wind a coil than thin but we have to keep the tolerance at bay. the machine should have a tolerance about 0.05mm. we will build a pneumatic air tailstock to support turning parts and keep them steady. we have yet to design a wire tensioner with shellac injection system and an optional hot air gun. after countless of hours 3D modeling in Solidworks this is the result:

Hello everybody, it's been a long time I had no thread in the forum. As you probably know we have been designing and building speakers for almost a decade in Iran for various of applications. If you have ever built a crossover network you probably know that the inductors are really pain in the butt to build specially when you need high quantities so the winding will be a job of attrition. this is why I decide to design and build a high torque winding machine with a CNC rotary and wire feeder mechanism to wind perfect lays inductors and autotransformers. I wanted to submit a thread here to let you know what I am doing and have your possible tips and ideas. maybe someone here want to build something similar so this would be a good clue to start. Last year we contacted a US company named Bachi that manufactures some very nice and advanced winding machine. we checked the shipping cost and importing taxes of this machine from US to Iran and it turned out to be something about $80K! our pocket was not that deep. the plan B was to buy a machine from China but after all we decided that we have to build it ourselves as we have experience in designing and building other type of machines.

I can't agree more about cabinetry you mentioned. I'm into speaker business in my own country and I just tried myself to see if I can build something similar to Volti when it comes to woodworking. with all the limitation in Iran - no paper-backed veneer, no veneer glue, no vacuum press I just had to invent everything from scratch! - I did it and the result turned out to be liked by just everybody here. building a Bruce Edgar type of horn is piece a cake (check this out: link). and building a folded horn by mixing a Belle and LS with a curved side is not that big deal. I did it to prove this could be done and here is the result: and now I have a more efficient way to laminate plywood to form curved panel and I can build a pair of these in less than two weeks actual working hours but I'm not gonna do this. I'm not gonna rip off someones ideas even if his idea is a rip off of Klipsch designs. but I guess we still can comment on the price right? I don't think putting together a Faital Pro 15PR400 with a BSM4592-Mid behind a wooden horn and a Faital Pro HF10AK behind an 18Sound XT120 elliptic horn and using a XOver from NRE and putting everything in folded cabinet Mark Kravchenko did in Hornresp is a big deal if you ask 4-5x of the real price. Maybe many of you are not aware of driver-making companies price lists. I do business with most of the European companies like Faital Pro, Beyma, B&C, BMS and some others but not mentioning the price details something like Vittora could be built for about 5000USD in my country with all the craftsmanship and all the drivers Volti uses including labor cost and everything. how about a version with a single piece curved walls from right to left? Rival is not an exception. it's a Cornscala with a little bit of cosmetics and high heels. You can still build a speaker using Eliptrac horn with a BMS driver and use some nice woofs and a tweeter like Faital Pro Hf108 or HF10AK and for about $2K you'll have a great speaker. just my $0.02

I've tested a dozen of expensive caps during the years. from Mundorf and Jantzen, Sonicap, Dayton, Duelund, Audyn, V-Cap, Clarity Cap, Auricap and some other general caps like Wima, Rifa, Erose, Epcos, Nichicon, Rubycon ... you name it. Sonicaps and Jantzen Superior Z-Cap are my favorites. I would not spend big money on caps anymore. even Jantzen Crosscap which is a pretty cheap caps sounds damn good. if I want something a little more expensive I would chose Sonicaps or Superior Z-cap. just my two cents

use Hypex Ncore and search no more

very nice build indeed. is there any calculator for this kind of horn?