Mr Tech Posted October 27, 2007 Share Posted October 27, 2007 First of all,let me say here that I AM NOT a woodworker.I am a mechanic (car guy) by trade and I do not like working with wood.But, sometimes, like it or not, you gotta do what you gotta do. When Iacquired my 95 OO Khorns a year or so ago, I knew that I didnt have anyusable corners in the living room (great room) where I wanted them to be, sofalse corners was the only way to go. I did a lot of research on the forum regarding false cornersand obtained a lot of useful information. I had very little extra space to workwith, so the corners could not be huge.Also, I regarded my Khorns as absolutely beautiful and I didnt want to uglythem up with ugly false corners. Not to mention the WAF.The best version of false corners I saw was Tigerwoodkhorns. His looked exactly like what I wanted mine tolook like, so I set out to attempt to replicate his design.I also decided that I didnt want to mutilate my Khorns with screws or anythingthat would permanently scar them, just in case I ever wanted to go back tooriginal. Shortly after I completed the false corner project I upgradedmy Khorns with ALKs ES networks, Trachorns and JBL 2404 tweeters, so now I have what is referred to as SuperKhorns. How do they sound? How do you think they sound? They soundawesome!They are truly the ultimate sound experience..this side of heaven. Quote Link to comment Share on other sites More sharing options...
Mr Tech Posted October 27, 2007 Author Share Posted October 27, 2007 I used ¾ cabinet grade oak plywood for the sides and¾ mdf for the bottoms.I didnt want any visible screws, so I glued the 2 sides together, used cornerbrackets on the inside and screwed the bottoms on from underneath. Quote Link to comment Share on other sites More sharing options...
Mr Tech Posted October 27, 2007 Author Share Posted October 27, 2007 Quote Link to comment Share on other sites More sharing options...
Mr Tech Posted October 27, 2007 Author Share Posted October 27, 2007 On the top corner bracket I attachedan L bracket. Quote Link to comment Share on other sites More sharing options...
Mr Tech Posted October 27, 2007 Author Share Posted October 27, 2007 I screwed a ¼ threaded stud onto the backboard of theKhorns. This is the only hole or screw that went directly into the Khorn andcould easily be reversed if necessary.As you can see, after careful alignment, the threaded stud would go through thehole in the L bracket where I attached a wing nut. This way, I could draw tight, viathe wing nut, the Khorn into the false corner to make a tight seal against thenew rubber seals I installed down the edges of the backboard. Quote Link to comment Share on other sites More sharing options...
Mr Tech Posted October 27, 2007 Author Share Posted October 27, 2007 This is whatthey looked like after phase one of the project.I might mention here that I spent an enormous amount of time experimenting withwood stains to get the best possible match. Make no doubt about it, it is verydifficult.I think I bought every stain color known to man and test stained bunches ofscrap wood until I found a good match. The left Khorn. Quote Link to comment Share on other sites More sharing options...
Mr Tech Posted October 27, 2007 Author Share Posted October 27, 2007 The rightKhorn. Quote Link to comment Share on other sites More sharing options...
Mr Tech Posted October 27, 2007 Author Share Posted October 27, 2007 The back andside of the left Khorn. Quote Link to comment Share on other sites More sharing options...
Mr Tech Posted October 27, 2007 Author Share Posted October 27, 2007 The back andside of the right Khorn. Quote Link to comment Share on other sites More sharing options...
Mr Tech Posted October 27, 2007 Author Share Posted October 27, 2007 Phase 2 ofthe project was making the new grill cloth frames.This was probably the most difficult and challenging part of the project.I was basically engineering this design on the fly. Lots of wasted wood. Here is theframe design I came up with using standard 1x2 wood. Quote Link to comment Share on other sites More sharing options...
Mr Tech Posted October 27, 2007 Author Share Posted October 27, 2007 In this pic you will notice that the right side is ata slight angle and cut with a corner notch.I accomplished this by gluing 2 pieces of wood together and then later makingan angular cut on them to offset the angle of the inner cut board.All this was necessary so that the outer edge of the grill frame would hug orfit onto the outer edge or the false corner. Quote Link to comment Share on other sites More sharing options...
Mr Tech Posted October 27, 2007 Author Share Posted October 27, 2007 The inneredge (Khorn side) of the grill frame conveniently fit perfect into the recessedarea where the original grill frame was. Quote Link to comment Share on other sites More sharing options...
Mr Tech Posted October 27, 2007 Author Share Posted October 27, 2007 Here is howit fits onto the Khorn and false corner. Also, worthmentioning is that I had to custom make each grill frame individually sincethere are minor differences in each corner and left & right side of eachKhorn. Quote Link to comment Share on other sites More sharing options...
Groomlakearea51 Posted October 27, 2007 Share Posted October 27, 2007 In a word - Beautiful Absolutely great idea for the wing nut to pull them into the corners. I'd bet that one could do that with a regular corner and a firmly attached 2"x2" Very nice work, and a great idea!!! Quote Link to comment Share on other sites More sharing options...
Mr Tech Posted October 27, 2007 Author Share Posted October 27, 2007 Next Ipainted them black. Quote Link to comment Share on other sites More sharing options...
Mr Tech Posted October 27, 2007 Author Share Posted October 27, 2007 In this picyou can see that I added a foam rubber strip to the side that butts up againstthe Khorn so as to help make a tight and rattle free fit. Quote Link to comment Share on other sites More sharing options...
Mr Tech Posted October 27, 2007 Author Share Posted October 27, 2007 Next, Iinstalled the grill cloth. Quote Link to comment Share on other sites More sharing options...
Mr Tech Posted October 27, 2007 Author Share Posted October 27, 2007 A finishedgrill frame. Quote Link to comment Share on other sites More sharing options...
Mr Tech Posted October 27, 2007 Author Share Posted October 27, 2007 The grill frames are attached to the false corner with3 black wood screws, virtually invisible. Quote Link to comment Share on other sites More sharing options...
Mr Tech Posted October 27, 2007 Author Share Posted October 27, 2007 On to phase3.The making of the triangular shaped wood tops. I chose tocut down the trailing edge of the corners to permit the wood tops to sit ontop of them and be equal with the top of the bass bin.I put a very thin piece of rubber weatherstrip on top on the corner to insulateit from the wood top. Quote Link to comment Share on other sites More sharing options...
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