False Corners Don't Have To Be Ugly. (PICS !!!)

[Mr Tech]

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 I
acquired my 95 OO Khorns a year or so ago, I knew that I didnt have any
usable corners in the living room (great room) where I wanted them to be,
so
false corners was the only way to go.

I did a lot of research on the forum regarding false corners
and obtained a lot of useful information. I had very little extra space to work
with, so the corners could not be huge.

Also, I regarded my Khorns as absolutely beautiful and I didnt want to ugly
them 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 to
look 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 anything
that would permanently scar them, just in case I ever wanted to go back to
original.

Shortly after I completed the false corner project I upgraded
my Khorns with ALKs ES networks,

Trachorns and JBL 2404 tweeters, so now I have what is referred to as Super
Khorns.

How do they sound? How do you think they sound? They sound
awesome!

They are truly the ultimate sound experience..this side of heaven.

[Mr Tech]

I used ¾ cabinet grade oak plywood for the sides and
¾ mdf for the bottoms.

I didnt want any visible screws, so I glued the 2 sides together, used corner
brackets on the inside and screwed the bottoms on from underneath.

[Mr Tech]

[Mr Tech]

On the top corner bracket I attached
an L bracket.

[Mr Tech]

I screwed a ¼ threaded stud onto the backboard of the
Khorns. This is the only hole or screw that went directly into the Khorn and
could easily be reversed if necessary.

As you can see, after careful alignment, the threaded stud would go through the
hole in the L bracket where I attached a wing nut.

This way, I could draw tight, via
the wing nut, the Khorn into the false corner to make a tight seal against the
new rubber seals I installed down the edges of the backboard.

[Mr Tech]

This is what
they looked like after phase one of the project.

I might mention here that I spent an enormous amount of time experimenting with
wood stains to get the best possible match. Make no doubt about it, it is very
difficult.

I think I bought every stain color known to man and test stained bunches of
scrap wood until I found a good match.

The left Khorn.

[Mr Tech]

The right
Khorn.

[Mr Tech]

The back and
side of the left Khorn.

[Mr Tech]

The back and
side of the right Khorn.

[Mr Tech]

Phase 2 of
the 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 the
frame design I came up with using standard 1x2 wood.

[Mr Tech]

In this pic you will notice that the right side is at
a slight angle and cut with a corner notch.

I accomplished this by gluing 2 pieces of wood together and then later making
an 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 or
fit onto the outer edge or the false corner.

[Mr Tech]

The inner
edge (Khorn side) of the grill frame conveniently fit perfect into the recessed
area where the original grill frame was.

[Mr Tech]

Here is how
it fits onto the Khorn and false corner.

Also, worth
mentioning is that I had to custom make each grill frame individually since
there are minor differences in each corner and left & right side of each
Khorn.

[Groomlakearea51]

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!!!

[Mr Tech]

Next I
painted them black.

[Mr Tech]

In this pic
you can see that I added a foam rubber strip to the side that butts up against
the Khorn so as to help make a tight and rattle free fit.

[Mr Tech]

Next, I
installed the grill cloth.

[Mr Tech]

A finished
grill frame.

[Mr Tech]

The grill frames are attached to the false corner with
3 black wood screws, virtually invisible.

[Mr Tech]

On to phase
3.

The making of the triangular shaped wood tops.

I chose to
cut down the trailing edge of the corners to permit the wood tops to sit on
top 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 insulate
it from the wood top.