Welcome, my friends, to what is my biggest (literally) project yet.

i would be worried about you being able to run all that from your 5.1 receiver...i have a pair of older klh floor-standing speakers (similar to the 9250b's, but with 15's) , they were weak off a High Current Cambridge audio azur(150w at 4ohm) and it looks like you should be demanding more power than that!?
I'm not, I picked up a Kenwood M1-D to do the job. //content.invisioncic.com/y282845/emoticons/smile.gif.1ebc41e1811405b213edfc4622c41e27.gif
 
re: tweeter , don't worry about it right now.
re: double baffle design, why not double baffle from bottom to top, instead is stops

at the woofers? The seamless design would be easier on the eyes.
Well, the tweeter is sealed back do I wouldn't have to chamfer anything to help it fit, but it'd be a tight squeeze to get the tweeter and the wiring through a hole that small that would also allow me to flush mount it. In short, the panels would have to be next to identical, and I'm not sure my woodworking abilities are that good for something with such a low tolerance for error as a flush-mounted tweeter. With a single baffle, it's fine. but to get the holes to line up exactly will be kinda trying for me. Any suggestions on how to do it easiest?
 
Well, the tweeter is sealed back do I wouldn't have to chamfer anything to help it fit, but it'd be a tight squeeze to get the tweeter and the wiring through a hole that small that would also allow me to flush mount it. In short, the panels would have to be next to identical, and I'm not sure my woodworking abilities are that good for something with such a low tolerance for error as a flush-mounted tweeter. With a single baffle, it's fine. but to get the holes to line up exactly will be kinda trying for me. Any suggestions on how to do it easiest?
For a double baffle? Glue the two layers together first, then cut the holes. Treat it like a single piece of 1.5" MDF.

 
Just a note on the tweet "overall looks like a stellar budget DIY project"

Quoted from Zaphs site...

Hi-Vi SD1.1 ($13) - "A" version tested. Nice performance for a tweeter of this price, and probably worth the few bucks more than the K1, but there are some consistency issues. Twin impedance peaks cause a slightly bumpy low end that smoothes out in box with typical baffle diffraction peaking. Slight rise in the top octave goes to flat a few degrees off axis. Make sure you have the shiny dome shown on the right. The dull one on the left measures horribly.

Also port that biatch to the rear, twin front ports make it look like a $20 swap meet wannabe prosound cab found in the dorm room of the local campus drunk.

 
Just a note on the tweet "overall looks like a stellar budget DIY project"
Quoted from Zaphs site...

Hi-Vi SD1.1 ($13) - "A" version tested. Nice performance for a tweeter of this price, and probably worth the few bucks more than the K1, but there are some consistency issues. Twin impedance peaks cause a slightly bumpy low end that smoothes out in box with typical baffle diffraction peaking. Slight rise in the top octave goes to flat a few degrees off axis. Make sure you have the shiny dome shown on the right. The dull one on the left measures horribly.

Also port that biatch to the rear, twin front ports make it look like a $20 swap meet wannabe prosound cab found in the dorm room of the local campus drunk.
Or one big port on the front... //content.invisioncic.com/y282845/emoticons/wink.gif.608e3ea05f1a9f98611af0861652f8fb.gif

 
Just a note on the tweet "overall looks like a stellar budget DIY project"
Quoted from Zaphs site...

Hi-Vi SD1.1 ($13) - "A" version tested. Nice performance for a tweeter of this price, and probably worth the few bucks more than the K1, but there are some consistency issues. Twin impedance peaks cause a slightly bumpy low end that smoothes out in box with typical baffle diffraction peaking. Slight rise in the top octave goes to flat a few degrees off axis. Make sure you have the shiny dome shown on the right. The dull one on the left measures horribly.

Also port that biatch to the rear, twin front ports make it look like a $20 swap meet wannabe prosound cab found in the dorm room of the local campus drunk.
Yeah, but you have to take everything Zaph says with a grain of salt. He may not like it, but the people buying it have all given it a perfect 5/5 //content.invisioncic.com/y282845/emoticons/wink.gif.608e3ea05f1a9f98611af0861652f8fb.gif

http://www.partsexpress.com/pe/showdetl.cfm?Partnumber=297-416&vReviewShow=1&vReviewRand=3432827#reviews

And I'll look and see how it looks ported to the rear w/ complete double baffle; it looks good to me aesthetically as it is. //content.invisioncic.com/y282845/emoticons/smile.gif.1ebc41e1811405b213edfc4622c41e27.gif

 
Let's just put it this way... I wouldn't want Zaph to design me a party speaker. //content.invisioncic.com/y282845/emoticons/tongue.gif.6130eb82179565f6db8d26d6001dcd24.gif

I doubt anyone is going to notice the bumpy low end or slight rise in the upper octaves when this speaker is being used for what it is designed for. //content.invisioncic.com/y282845/emoticons/cool.gif.3bcaf8f141236c00f8044d07150e34f7.gif

Oh yeah, I don't think the ports look too bad at all. Although a single 6" might be a little more aesthetic. Personally I would just do a simple slot but I can see how some might think it's ugly.

 
Aight y'all, you convinced me to go double baffle, but what about the ports?



or



Your call, I like it either way; ports front make it look a bit meaner and gives it a more "raw" look, ports rear makes it look like an old JBL speaker in a listening room from the 80s. Either way, it's a win. //content.invisioncic.com/y282845/emoticons/smile.gif.1ebc41e1811405b213edfc4622c41e27.gif

 
Yeah, but you have to take everything Zaph says with a grain of salt. He may not like it, but the people buying it have all given it a perfect 5/5 //content.invisioncic.com/y282845/emoticons/wink.gif.608e3ea05f1a9f98611af0861652f8fb.gifhttp://www.partsexpress.com/pe/showdetl.cfm?Partnumber=297-416&vReviewShow=1&vReviewRand=3432827#reviews

And I'll look and see how it looks ported to the rear w/ complete double baffle; it looks good to me aesthetically as it is. //content.invisioncic.com/y282845/emoticons/smile.gif.1ebc41e1811405b213edfc4622c41e27.gif
People give total crap a 5/5 a lot of times haha. Also I just pointed it out so you can watch out for the different dome types. He has tested both and the one version SUCKS.

 
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