You might be able to use a rotary file or a hand file to make your cuts, then sanding and such.  You can use a VARIAC to slow your tool's speed if you need. For high-speed tool steel (HSS) cutting mild steel needs to stay ~ 72 FPM. Bronze can be cut at a much higher speed: ~ 200 FPM and brass higher than that. (from the Machinery's Handbook many years ago) N= 12 x FPM / Pi x D N = RPM D = Diameter of tool (drill, cutter etc) or workpiece (lathe work etc) Now, put in the numbers for a 1/2" drill bit: N= 12 x 72 / Pi x 0.5  N = 550 RPM        One easy rule to put in your pocket, in your head or tell someone who will remind you: A 1/2" (0.500") HSS drill bit can turned at 500 RPM into mild steel. Double the drill size, cut the speed in half; cut the drill size in half, double your speed. It all comes back to ~ 72 FPM. Just remember 500 = 500 and do any fraction or multiple of that...3/8" = 750 RPM etc.  

This ^^^ If your brother is not chasing the what ifs, then he can rest assured that he has all that he needs. With the new, bigger and better everything, Roy and his team got the CW4 right.  I'd still have to listen to them. 

Totally different woofers and everything else. The CF4 has much larger horns and drivers. The KLF30 is a 3 way TMW vs the CF4 is a two-way WTW arrangement. The KLF30 has been known more as a party speaker and the CF3 and CF4 are known to be in the HiFidelity arena.  I have owned pairs of both and have ABed them. I still have a pair of each and I should AB them again. 

The brass will heat up while cutting with a router and melt the epoxy which melts around 300F. Everything will then get "icky-poo-poo" and you will be very unhappy. JJK

Hi All, I have always been very careful with my Klipsch systems, also with my Klipsch THX 5.1 set. Sadly recently something heavy fell down on my control pod ( the small standing model with orange leds in it ) and bashed the control pod to bits. Luckily I was able to save the print inside and that still works, but the control pod housing is history. I have tried to find one on eBay, no luck. Contacted Klisch themselves, no luck Bought a Ultra pod - only to learn that apparently they are not compatible -, so that's useless. So does *anyone* here have a - even broken - control pod that I can take apart to fix my control pod. All I need is the housing actually.   attached is a picture to clarify which one I am looking for Thanks for any help you can offer  

If your brother is enthusiastic about the CW4, then he should definitely keep them for a longer period of time in my view. In my opinion, the aim of a good speaker is to make you forget about this speaker more and more and to open the window to the music more and more. That's why I've had my main speaker sets for 30 years in some cases. If your brother just got used to the CW4 a year or two ago, then everything would start all over again, all the brain work of listening and empathizing. What would he get instead when now changing gear in the phase of becomming more and more familiar with it? A short-term show effect of the “different again” impression. It can go well, but it can also end very badly. In my experience, either the love for a speaker increases with longer and longer listening (a paradoxon because you „forget“ the speaker more and more at the same time) or when changing again you feel “entertained” at the beginning because of the short-term show effect, or you talk yourself up about the new speakers because you have to justify spending the money. But...a strange feeling creeps in that something is not right. Just as you learn to love one loudspeaker, you can experience certain disturbances with another loudspeaker that become more and more noticeable and absolutely annoying over time. To be honest, it's not worth the experiment. BTW Buying new CW4s again after a dissappointing experience with other speakers would always be more expensive for your brother, or they would be second-hand speakers that don't come from the same family. Just my two cents.

Just looks like a reconfiguration of the KLF series.

Preface:  I'm going to make a display box for an old family bible.  Wouldn't surprise me if it was 150 or more years old.  My understanding is my grandparents had it when my father was a child (and it was passed down to them).  My dad is now 95... I've got a swirl of ideas so this is me throwing some spagatti onto the walls to see if this is even viable.   one idea is to insert a decorative (say, 1/4") brass rod so the "dot" would show against the (probably walnut).  Purely decorative.  Don't yet know where the rod might go....but I know I'll be routing the top/lid section.....which had me wondering.....   Could one drill the hole, say, 1/2" deep, take a 9/16th's length of brass rod, set it in epoxy but now it's sitting a bit proud.  Could you THEN take the router and have the router trim the rod down flush with what/how ever you are routing?  (route the wood and brass together)   Part of me says probably but you'll likely ruin your bit (wouldn't a carbide live through that?)  If it worked BUT ruined the bit, that might be an acceptable tradeoff as you can always buy another bit.   Another part says it might bugger up the brass.  Probably won't leave it as clean as I'm picturing it in my mind.   I'm thinking there are more reasons to NOT do it than to try.  But if my "creative side"  (HAHAHA  That's a joke!!!)   Anyway, if I lean to wanting to do something like that, I'm wondering how well it might work or other issues.        

Maybe someone could design a horn speaker that has less footprint.  

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