QUAD Sewn-On Leadwire Pics =]

[SPLaudio 5,000+ posts]

WOW!

i have folded cones,shredded spiders,broke formers in 2 but never burnt up a lead wire.

i feel deprived

 

[TeamPSI 10+ year member]

i got ya dave.
with alum coils do you solder or wrap and glue?

Solder for sure. People who just wrap them up just don't know what they're doing. (not an attack, but just the truth) The proper way to do this is to solder with the proper solder and flux combination, at the proper temperature.

I'm going to add the soldering flux we use to solder to aluminum to our web store tonight as a matter of fact! //content.invisioncic.com/y282845/emoticons/biggrin.gif.d71a5d36fcbab170f2364c9f2e3946cb.gif

 

[SPLaudio 5,000+ posts]

k just asking cause i know some do it 1 way or another...

 

[sundownz Pro Seller]

Good deal Dave... trying to solder aluminum coils without that flux = FTL

 

[TeamPSI 10+ year member]

Good deal Dave... trying to solder aluminum coils without that flux = FTL

Hahaha, A mutual friend was telling me about a call he got from you quite a while ago.

He said that you had ended up burning a hole though a cone trying to get the solder to stick to the aluminum!! //content.invisioncic.com/y282845/emoticons/biggrin.gif.d71a5d36fcbab170f2364c9f2e3946cb.gif

It definitely makes the difference huh!?

 

[sundownz Pro Seller]

Yes it does *laughs*

Prior to that time I had only soldered leads onto copper coils which are easy //content.invisioncic.com/y282845/emoticons/smile.gif.1ebc41e1811405b213edfc4622c41e27.gif

 

[SPLaudio 5,000+ posts]

i was originally told to wrap tite and glue. i have always added solder to the leadwire but it didnt stick good. i had 1 failure and it burnt the coil lead off, built many subs this way without problems though. just tring to step up my game i started soldering. i have to throw alot of the flux i got at it to work. so today gonna get some military grade liquid flux instead of paste and try that...

 

[sundownz Pro Seller]

With the right flux it solders quite well -- when David puts it up for sale get some. WELL WORTH IT //content.invisioncic.com/y282845/emoticons/smile.gif.1ebc41e1811405b213edfc4622c41e27.gif

 

[SPLaudio 5,000+ posts]

will be getting hold of ya dave if the flux i'm getting today dosnt work well. but this flux is used @ work for voice coils so will see...

 

[TeamPSI 10+ year member]

Try it and let me know. Most fluxes claim that they'll work on aluminum, but most all of them don't do much more than get it wet.

I put it on the site f/s btw.

 

[SPLaudio 5,000+ posts]

ok cool thanx dave.

 

[2003F150 10+ year member]

So dd putting the leads in between the spiders is not a good thing??? They seem to do fine imo. You do have a point with them causing friction there though. Very interesting. DD uses quad leads stock on all theie lines im pretty sure. Nice looking subs by the way.I have never had a dd lead burn or break at all.

 

[TeamPSI 10+ year member]

So dd putting the leads in between the spiders is not a good thing??? They seem to do fine imo. You do have a point with them causing friction there though. Very interesting. DD uses quad leads stock on all theie lines im pretty sure. Nice looking subs by the way.I have never had a dd lead burn or break at all.

Friction and non-linearity.

DD's woofers are not "high excusrion" subwoofers in my opinion. They use smaller spiders with smaller rolls than most. They also use lots of very soft spiders in big thick stacks (up to 12+ spiders on 1 sub!) They work great within their limits, but those limits are fairly small compared to what most of us are doing these days.

Holding excursion to around 2" p-p allows them to get away with doing their leads like that. The minimal movement of the spider keeps the, almost flat layer of leadwire, from snapping due to being stretching out.

If they ever decide to move on up and make some HIGH excursion subwoofers, they will have to adapt a new method of running leads to the coil, at least from where I'm standing.

Atomic has that problem with their leads. I have persoanlly repaired somewhere around 50 of their woofers with no other damage to them other than the leads being broken in-between the spiders.

It think Fi audio has now moved away from that same method of running their leads. Im not sure why, but if I had to guess...

If you take a look at the top manufacturers of high excusrion products on the market right now, they are all either still free-floating leads, or they're beginning to use leads made just like what we do.

Keep your eyes on what hits the market in the years to come, and you'll see even more manufacturers moving to sewn-on leads.

 

[sundownz Pro Seller]

Sewn-On for the win... agreed.

I have a DD here now with blown leads between the spiders, actually.

 

[TnT_Sounds 10+ year member]

That's correct to an extent.
I have seen a lot of leadwire burning from high powered burps, as well as just being yanked apart when they are set up with different styles of leads. Things like smashing the leads inbetween the spiders, free flloating them, etc can also cause undue stress, friction and heat to be applied to the leads.

Being sewn down reduces the movement of the lead itself. Just keeping them from flopping all around, smacking into the cone and spiders makes a world of difference. In most cases, up to twice the power handling from the start vs free floating leads when using the same size and amount of leadwire.

When they are smashed inbetween the spiders, friction is a killer. Heat builds up, burns the spider, etc. Not to mention that when placed inbetween the spiders, the leads are not allowed enough length to stretch under high excursion, causing them to be completely ripped in half!

This way also causes non-linearity in the spipder itself. No matter what anyone says, a bunch of wire smashed inbetween the spiders has a big effect on the suspension.

As for the coil to lead connection, you have to remember that this happens in a region of the speaker that does not move. This connection is made and then glued in place. The coil itself is more or less a hunk of material. It moves as a whole, but the small individual strands make up and entire unit. If the actual strand of wire was under stress from movement, friction, etc, then sure.

The leads are under high amounts of stress at all times during play, therefore they need to be a lot more resistant to these conditions.

Hmmm. About the pressed leads configuration, the leads are stitched in and have their own cavity in which they 'ride'in. Thus is why clipping and subsonic filters are VERY key.

If the tinsel is the exact same length as the spiderweaves..height etc. How could it not be 'long enough' under 'highexcursion'? The spider moves X amount...the leads that are woven inbetween thespiders move X amount because they create a hill/valley that they ridein/on.External leads I prefer..but, they break...to make things more idiot proof the integrated leads inbetween spiders do not break as much andare more abuse tolerant