rll Posted January 9, 2010 Share Posted January 9, 2010 Last winter I put together this pair of Cornscalas. http://community.klipsch.com/forums/t/115820.aspx?PageIndex=1 While they sounded very nice, and my wife thought they looked great, I thought they were rather amateurish. Even though I have very little practical experience and skill, I knew I could do much better, so I began to look at those as prototypes. One consideration was to strip the original cabinets and veneer them. But I also began to think about replacing/upgrading the squawker horn. The layout of the motorboard prohibited that because the woofer cutout is too high. So I knew I'd be going back to square one. With that decision made, I began to wrestle with which design to build - a Cornwall cabinet or a something like Bob's original Cornscala using a k400/401 or something else. I eventually decided on the Cornwall II cabinet, with the woofer lowered. This configuration allows me to use the ph800 for the time being, with the option of replacing it with a Fastrac later. I don't have an Eye-gor, but I have Andy. He's not good at assisting, but loves to watch. I included this photo because it gives you a better idea of the color. In most of the photos to follow, the flash makes them look more red than they are. I did not chronicle the construction of the cabinets, but let me say that I learned from my experience building the first pair. My neighbor Harry, who loaned me some tools and assisted often, said any cabinet maker would be satisfied. Quote Link to comment Share on other sites More sharing options...
rll Posted January 9, 2010 Author Share Posted January 9, 2010 Assembled. Quote Link to comment Share on other sites More sharing options...
rll Posted January 9, 2010 Author Share Posted January 9, 2010 This picture does not do them justice, makes them look too red and splotchy, which they are not. What I want to show here is how the grain on the two side panels matches, and how it flows up to the top. I followed Marshall's instructions on finishing found here: http://forums.klipsch.com/forums/t/117315.aspx?PageIndex=1 . I also picked up Bob Flexner's book Understanding Wood Finishing and studied it. I sanded these with 150 grit with a random orbital sander. Thoroughly cleaned them by wiping, vacuuming, then a final wipe with mineral spirits. Gave them a liberal wipe of Gunstock, which I let sit for 15 minutes before wiping off. Then wiped them with a 2:1 mixture of Gunstock and Special Walnut, done twice. Let them rest for 24 hours before giving them a liberal wiping of 1:1 Watco Teak and Watco Medium Walnut oil, also twice. Quote Link to comment Share on other sites More sharing options...
rll Posted January 9, 2010 Author Share Posted January 9, 2010 The right, with grille.... Quote Link to comment Share on other sites More sharing options...
rll Posted January 9, 2010 Author Share Posted January 9, 2010 and the left. To build the grilles I followed Marshall's instructions in this thread: http://forums.klipsch.com/forums/t/110684.aspx?PageIndex=1 . We are very pleased with the way these turned out. Quote Link to comment Share on other sites More sharing options...
rll Posted January 9, 2010 Author Share Posted January 9, 2010 A side/rear profile. Quote Link to comment Share on other sites More sharing options...
rll Posted January 9, 2010 Author Share Posted January 9, 2010 Rear showing the terminal cups. Quote Link to comment Share on other sites More sharing options...
rll Posted January 9, 2010 Author Share Posted January 9, 2010 Andy approves! Quote Link to comment Share on other sites More sharing options...
rll Posted January 9, 2010 Author Share Posted January 9, 2010 A quick word about the cables. Without intending to start a debate, I fall into the simple, inexpensive, yet effective camp. That said, I like something with a professional, finished look. I recently put these together, at a cost of less that $1 per foot, plus connectors. All components came from Parts Express. Start with the professional 13 awg speaker wire: http://www.parts-express.com/pe/showdetl.cfm?Partnumber=100-481 Covered with 1/4" expandable sleeving: http://www.parts-express.com/pe/showdetl.cfm?Partnumber=082-316 Cable finished with 9mm Cable Pants: http://www.parts-express.com/pe/pshowdetl.cfm?&Partnumber=082-778 Banana plugs: http://www.parts-express.com/pe/showdetl.cfm?Partnumber=091-1260 Quote Link to comment Share on other sites More sharing options...
rll Posted January 9, 2010 Author Share Posted January 9, 2010 A closeup of one end. Very clean. Randy Quote Link to comment Share on other sites More sharing options...
Invidiosulus Posted January 9, 2010 Share Posted January 9, 2010 Very nice. I really like the veneer and finish on those. -Josh Quote Link to comment Share on other sites More sharing options...
Marvel Posted January 9, 2010 Share Posted January 9, 2010 Randy, Very nice! I bet there is a much higher WAF as well. The veneer job looks outstanding. Bruce Quote Link to comment Share on other sites More sharing options...
rll Posted January 9, 2010 Author Share Posted January 9, 2010 Very nice. I really like the veneer and finish on those. -Josh Josh, Thanks. My love of walnut goes back to junior high wood shop and a chess table I made back then. The smell of walnut working on this brought back many memories. Randy Quote Link to comment Share on other sites More sharing options...
rll Posted January 9, 2010 Author Share Posted January 9, 2010 Randy, Very nice! I bet there is a much higher WAF as well. The veneer job looks outstanding. Bruce Thankyou Bruce. Oddly enough, it was the other way around at first. She was initially skeptical, said the others were just fine. When I got to a point where I had to remove the components from the others, she got quite anxious for me to finish them. She's grown fond of the improved sound quality over the KG4s. When I put them side by side and did an A/B comparison, she was hooked. With the veneer, I thought long and hard before I cut the pieces. I laid the sheet out several times, in the end I let the sheet tell me where the cuts should be made. Even then, before I cut it, I had Harry come over for a consultation and he liked it. I'm very happy with how it was laid out. As Greg Roberts would say - details. Randy Quote Link to comment Share on other sites More sharing options...
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