1st attempt at kerf port..

HawaiianBassHed
10+ year member

CarAudio.com Elite
1,362
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Pahoa,HI
its kind of a pita, I did a couple practice pieces the 1st one was almost looking like it was gonna crack so I wasn't ready to do the actual port piece. but the second one looked better so I decided to go for it.. I used a 35lbs olympic weight to shape the test piece and traced it onto the side of the box, then I cut the port notches in exactly the same places and same number and being 22.5" wide it didn't bend quite as easily as the 5" wide test piece so I ended up just winging/freehanding it but it works I suppose lol. doing a second box and making it match is gonna be the hard part. gonna run twin boxes with an AQ HD3 15" in each run off a pair of xp1400ds strapped 1ohm to each sub so 4 amps total. this is all going in my wife's 07 expedition.

oh box is about 4.5 cubes 76ish inches of port (the straight edges that is) tuned to about 42hz. hoping to get close to a 150 with this setup //content.invisioncic.com/y282845/emoticons/smile.gif.1ebc41e1811405b213edfc4622c41e27.gif also will be double layering the top and bottoms of the box to make it more ridgid... may even use something besides mdf for that haven't decided yet still gotta resin the interior tomorrow, did this all today from getting it cut all crappy at home depot to stacking weights on it to bend the box to make the lid semi-flush LOL the kerfing took the longest by far.

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can't wait til it's done, have a tipro in there now in a 5 cube box tuned to 28hz on a single xp1400d since I didn't get my new batts yet otherwise I'd run a pair of xp1400ds to it //content.invisioncic.com/y282845/emoticons/biggrin.gif.d71a5d36fcbab170f2364c9f2e3946cb.gif here's vid of it going

http://vids.myspace.com/index.cfm?fuseaction=vids.individual&VideoID=63896620

I'm gonna test the tipro in this box if my recones aren't in by the time it's done. just to see if it's louder than the other box and by how much and see if I even like it lol.

 
it was the 2nd test piece I think. the 1st one I had sitting against an old hc2400... they're both about the same. 3rd piece is the actual box //content.invisioncic.com/y282845/emoticons/smile.gif.1ebc41e1811405b213edfc4622c41e27.gif yeah, as long as I can make another one to match I'll be happy lol. I marked it all up the same so cuts will be the same amount, same space apart, same layout, just the bending identical to the 1st box is gonna be the pita LOL...

 
What is that like 2 cubes after displacement??? Port takes up a TON
box is 32x24x16

30.5x22.5x14.5=5.74 cubes

port is 22.5x4.25"(3.5+.75)x21"= about 1.26 cubes with the flare...

so box is about 4.4 cubes@41hz.. I actually screwed up a little and it ended up getting smaller as I couldn't make the flare small enough...

 
as deep as u can without cutting completely thru the wood, maybe lik 1/16" uncut... I cut a hair less and wish I cut a hair more... it was a pita to bend...

 
nope, I just woke up... box is 32x24x16" I'm a tard... dammit boostNbeer, your killing me! I didn't fuk it up that bad... it's like 4.5 cubes at 40hz... AFTER displacements... just woke up and was like, wtf, no, my box isn't that small, then just recalc'd it in my head... then went and grabbed the tape to confirm what I had written down that I went off of yesterday LOL.. whew, scurred me thurr....

 
more pixors... finished the box it came out ok, then did the second box it came out better as I did 2 additional cuts...

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rounded over and interior completely glassed. I used clear casting wax free resin and self level it in the box one side at a time some sides ranges from 1/8"-3/16" thick as I wasn't measuring the glass just mixing batches in a cut in half 2 liter and the sides vary in surface area...

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slapped one in the expedition with the TiPro since I didn't recone my HD3s yet and the recones just came in about 3 hours ago...

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dry fit them in the motors/baskets... I only have one basket spacer so I'm waiting to see if DJ says if they built them to use the spacer or not. then I'll go ahead and recone them hopefully without as I only have one spacer if not I'll space the other one with nuts or something as their's a comp here saturday and I plan on being it in...

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1st time I seen regular american HD3s with the new cones, when I opened the boxes I automatically assumed someone made a mistake, until I read the writting on the formers/coils lol.

 
here's a quick vid of initial testing of the box with the TiPro on a single xp1400d since my batts aren't charged yet //content.invisioncic.com/y282845/emoticons/frown.gif.a3531fa0534503350665a1e957861287.gif

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my 6v 420ah batts sitting next to an old kinetik 2400 I have laying around which I use as a 3rd hand for holding wood to cut or as a table sometimes to cut on lol.

http://vids.myspace.com/index.cfm?fuseaction=vids.individual&videoid=100595905

http://vids.myspace.com/index.cfm?fuseaction=vids.individual&videoid=100595873

the AQ's will have a pair of xp1400ds to each sub. strapped at 1ohm, so .5ohm per amp... should get pretty loud. 4 Trojan L-16 category batts, but they're used and pretty crappy condition so I'm not really sure how much power they'll actually put out. I've been charging one pair for about 3 days, so now the second sets turn. I'm using a C-tek cs7000 or something like that. good automatic charger. I have a manual charger loaned out but I think it may be on it's way out. I ALMOST got a new manual one today that has 6v and 12v and 10,2 or 60a iirc charging but I don't have much money as I've been laid off for a few months... so I decided to just skip the manual charger and use the c-tek for all it's worth LOL. I've used it on optima's and such plenty of times and it's a good charger. just not sure if it'll do anything to these beat up monster 420aH batts... IF I can even restore them to half their rated output I should be ok on power imo...

 
coil guide? the spacer between the basket and motor? that thing doesn't have anything to do with a coil imo besides setting the basket further from the motor so less windings would be in the motor //content.invisioncic.com/y282845/emoticons/confused.gif.e820e0216602db4765798ac39d28caa9.gif

shims being the paper thin clear plastic? I can fit like 2 in their it's so tight and yummy //content.invisioncic.com/y282845/emoticons/tongue.gif.6130eb82179565f6db8d26d6001dcd24.gif

 
Looks like they came out good, especially for your first try. Those boxes are freakin' huge! lol

Should be loud though...you might want to try putting a piece of pvc (2" would be good) over the inside edge of port though. I built a similar box to test in my truck and I gained .4db by adding the pvc (one sub). Let us know how you do at the competition...looks promising.

 
I did that with my 18" MT box, but I used a 1.25" or so pvc and cut it with my dads Dado blade back when he lived in kona side. he was pissed to say the least.. I actually thought about doing it to these boxes but don't have a dado blade. I made still do it but it's a huge PITA plus I glassed it on last time... it's definitely worth the gain. but I don't know if I can get them in there at this point //content.invisioncic.com/y282845/emoticons/frown.gif.a3531fa0534503350665a1e957861287.gif

 
oh did the recones with 5 minute epoxy //content.invisioncic.com/y282845/emoticons/laugh.gif.48439b2acf2cfca21620f01e7f77d1e4.gif we'll see if they even hold together last time they did but I used the tube that mixes on the way out, this time it was getting tacky already by the time I got the recones in. but they look really nice as point source mids //content.invisioncic.com/y282845/emoticons/biggrin.gif.d71a5d36fcbab170f2364c9f2e3946cb.gif

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HawaiianBassHed

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