popbumper Posted July 18, 2005 Share Posted July 18, 2005 All: I just spent about 45 minutes "inspecting" my '76 Cornwalls, taking measurements and doing drawings. These cabinets are DECEPTIVELY simple to rebuild, I am going to sketch them in ACAD tomorrow and try to cut myself a set this week on the CNC. This will be a fun project - and I work with a guy who is a master wood craftsman, so veneering is not gonna be a challenge. I will post pics when I get this done, stay tuned! Chris Quote Link to comment Share on other sites More sharing options...
colterphoto1 Posted July 18, 2005 Share Posted July 18, 2005 already been done, check out 'lets start a cornwall drawing' I think in mods section. But good luck with your DIY project. It's always fun to DIY! Probably one or members already has the CNC setup, not sure who. Michael Quote Link to comment Share on other sites More sharing options...
jwc Posted July 18, 2005 Share Posted July 18, 2005 ---------------- On 7/18/2005 8:34:18 PM popbumper wrote: All: I just spent about 45 minutes "inspecting" my '76 Cornwalls, taking measurements and doing drawings. These cabinets are DECEPTIVELY simple to rebuild, I am going to sketch them in ACAD tomorrow and try to cut myself a set this week on the CNC. This will be a fun project - and I work with a guy who is a master wood craftsman, so veneering is not gonna be a challenge. I will post pics when I get this done, stay tuned! Chris ---------------- Dude, save yourself some money unless you have free access to the CNC stuff. Heck, print this out and take to Home depot. This includes everything. You can use the pine 3/4 inch "mounting strips" and cut those yourself in the Home depot home molding section. You could have them together by this weekend! ftp://www.jwcullison.com/Cornwall/Cornwall%20dimensions-typed.doc jc Quote Link to comment Share on other sites More sharing options...
popbumper Posted July 18, 2005 Author Share Posted July 18, 2005 Michael, JC: I was certainly aware of the previous "Cornwall drawing" thread, I just got a wild hair tonite and figured I'd take some quick measurements myself. These cabs are very simple. Since I am the guy who runs the CNC at work, and also writes the code, it's no biggie. I can probably draft the panels up and get them all cut in about an hour. I can have a set together by this weekend - then I need to veneer them, and throw out some cash and put together some of Al's Cornwall networks. Then I need to sit back and experience some audio nirvana!! Chris Quote Link to comment Share on other sites More sharing options...
colterphoto1 Posted July 18, 2005 Share Posted July 18, 2005 You WILL be happy with the results. Have you heard the Mighty Cornwalls before? Anyone who has em LOVES em! Have fun. Michael Quote Link to comment Share on other sites More sharing options...
jwc Posted July 18, 2005 Share Posted July 18, 2005 I will "stay tuned". Quote Link to comment Share on other sites More sharing options...
popbumper Posted July 18, 2005 Author Share Posted July 18, 2005 Michael: There's a local guy who has an all Corn theater, I listened to it two years back; quite amazing! As for me, I hooked up one of my corns last night on the right channel of my system, with the left being a Forte. Interesting "A/B" - the Corn has a metal horn midrange, and I found that the Cornwall was WONDERFUL in orchestration where BRASS was concerned, and the Forte was excellent with STRINGS. Now, the Corn is '76, stock "B" network, no rope caulk, etc., so my work is ahead of me. Can't wait to build new cabs, put in Al's network, caulk the horns, etc. to see what happens! Chris Quote Link to comment Share on other sites More sharing options...
popbumper Posted July 19, 2005 Author Share Posted July 19, 2005 Evening all: Update - took the drawings for the Corn cab to work today and actually cut one cabinet. Tomorrow I will mitre the top/bottom/sides, and begin the framework. The motorboard turned out very nice, except for being very SLIGHTLY off the original - not far enough to even know unless you put the new on top of the old. I will correct the drawing tomorrow. I plan to assemble the first cabinet tomorrow, and get a second one cut. The beauty of the CNC is super clean edges. Material? I cut these from 7 layer MDO playwood - a 7 layer plywood with a very hard "coating" on either side. Ever seen an interstate highway sign? That's MDO with a vinyl applique. VERY durable, tough stuff. It will take a veneer or paint readily. As soon as I have some pics (likely tomorrow), I will begin posting them. Looking forward to having some new Corn cabs. It's great to have access to a tool like a CNC! Chris Quote Link to comment Share on other sites More sharing options...
TommyC Posted July 20, 2005 Share Posted July 20, 2005 Hey Chris. Are you gonna swap the innards from your '76 Corns to the new cabinets or buy all new stuff? I have been considering building some Slightly modified Heresys but don't wanna scavenge my nice HWOs for parts. ps. you still in Richardson? Quote Link to comment Share on other sites More sharing options...
popbumper Posted July 20, 2005 Author Share Posted July 20, 2005 Tommy: I'm gonna swap the innards, build brand new networks, rope caulk the mid horns, etc. Basically put all the stuff in a new cab. In fact, The first cab is about 75% complete as of today (need to add internal shelf, paint the motorboard and rear panel, and veneer). Gonna shoot for having the first done in a week, with the other close behind. Yes, I am still in Richardson! Chris Quote Link to comment Share on other sites More sharing options...
TommyC Posted July 21, 2005 Share Posted July 21, 2005 ---------------- On 7/20/2005 6:51:16 PM popbumper wrote: Tommy: I'm gonna swap the innards, build brand new networks, rope caulk the mid horns, etc. Basically put all the stuff in a new cab. In fact, The first cab is about 75% complete as of today (need to add internal shelf, paint the motorboard and rear panel, and veneer). Gonna shoot for having the first done in a week, with the other close behind. Yes, I am still in Richardson! Chris ---------------- Cool. I would love to see the finished project. Quote Link to comment Share on other sites More sharing options...
popbumper Posted July 21, 2005 Author Share Posted July 21, 2005 This morning: Painted the motorboard, back panel and cab edges. Installed shelf. Fastened motorboard to front. Researching veneer, will pick up a 4x8 sheet of Walnut probably tomorrow. I DO have pics of this stuff, no way to send from work (old computer), will share soem pics tonite. It's looking great! Chris Quote Link to comment Share on other sites More sharing options...
popbumper Posted July 22, 2005 Author Share Posted July 22, 2005 OK all - here are some pics of the Cornwall cab I am building. These certainly are not perfect pics, and the format may be off, but you'll get the idea. First pic is the raw cabinet - four sides. Quote Link to comment Share on other sites More sharing options...
popbumper Posted July 22, 2005 Author Share Posted July 22, 2005 Here the front and rear cab edges are being painted with black lacquer. The front edge of course will have veneer once all is said and done. Quote Link to comment Share on other sites More sharing options...
popbumper Posted July 22, 2005 Author Share Posted July 22, 2005 The motorboard has been painted and installed in the cabinet. Tolerances are very tight and things fit well! Quote Link to comment Share on other sites More sharing options...
popbumper Posted July 22, 2005 Author Share Posted July 22, 2005 Back panel, painted. I av eyet to add the input terminal block, and drill the screw holes. The screw hole locations have been marked on the backside. Quote Link to comment Share on other sites More sharing options...
colterphoto1 Posted July 22, 2005 Share Posted July 22, 2005 Chris, while you're in there, are you going to install any further bracing? I'm thinking specifically about a 1x2 poplar or metal L to stiffen the motor board. Also, are you going to get into the Cornwall xover business? Michael Quote Link to comment Share on other sites More sharing options...
popbumper Posted July 22, 2005 Author Share Posted July 22, 2005 This is the internal shelf added after all else has been done. Note the motorboard has also been painted at the back - not as original - but I painted both sides so I could choose the best outward facing side. Keep in mind that this is a PROTOTYPE build, any and all "issues" will be addressed on the next build. Thanks all for your interest I will follow in a few days with pics showing stuffing, parts placement, and veneer. Chris Quote Link to comment Share on other sites More sharing options...
popbumper Posted July 22, 2005 Author Share Posted July 22, 2005 Michael: Thanks for asking. I would be willing to add enhancements given the need for some improvements on this platform. If you can be specific on what you think is appropriate for stifeing, say so. Also I CAN cut "vertical motorboards" if someone will supply me with the hole locations - this would allow me to build center channel cabinets. Yes, I can also do crossovers, shouldn't be a problem. These will certainly use my PCB's. Chris Quote Link to comment Share on other sites More sharing options...
jwc Posted July 22, 2005 Share Posted July 22, 2005 PopBumper, Nice work. I noticed that 3/4 inch mounting brace on the top/front of the port shelf. Was that in your other Cornwalls? Quote Link to comment Share on other sites More sharing options...
Recommended Posts
Join the conversation
You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.