As my DIY speaker set (front 5) is now complete, I thought I'd post some pictures from the long build process.
The drivers I used are the Zaph ZA14W08 midbass woofer, and a Vifa titanium dome tweeter with custom crossovers, part of the Zaph Audio ZA5 lineup. The cabinets are all custom made from 3/4" MDF, with a Walnut Veneer.
I need to buy some more drills...
Poor man's table saw.... This actually worked great, provided you have a square piece of wood. FYI, Home Depot sells nice 2' x 4' MDF panels that are perfectly square, as opposed to Menards' cut down 2' x 4' panels that are not square and will result in shitty panels.
Here is the wood for the front 2 bookshelf speakers. Note; the wood isn't stacked straight; there was virtually no variation in the panel sizes
Routed the front panel for the drivers
Test fitting drivers... So far so good
Gluing and screwing cabinet #1
Mounting the drivers and crossovers in cabinet #1
Its time for a new router... Old and busted
A much easier routed center channel front baffle
Veneering the center channel in a beautiful walnut veneer from Woodcraft
Layer 1 of varnish/poly/whatever it is. Starting to look a little better
God I love walnut
Removable back panel for easy access to the crossovers, should a wire ever come loose
And now, time to make the stands. A few pieces of MDF + this:
And you get these:
Which you can glue together with some dowels like this
and glue on some other panels like this:
And end up with speaker stands that cost almost nothing!
I know its hard to believe, but this actually isn't real stone.
All together now, in the room. (Yes, the subwoofers are OBVIOUSLY out of place, I know, just be patient)
Last, but DEFINITELY not least, the subwoofer cabinets are complete! (somehow I managed to not take any photos of the subwoofer cabinets being built)
And there's little Bailey saying hello
Overall, I'm VERY happy with the result. It took about 5x longer than I expected, but it really made me appreciate the speakers. Knowing that the drivers/crossovers alone cost the same as the set of Klipsch speakers I was ready to buy kind of bumps the perceived value through the roof, now that I see how much work is actually involved in putting them together.
These speakers sound better than any speakers I've ever heard in my life. Granted, I haven't heard all that many different speakers, but they still sound awesome. The subs are still my old car audio subs, which ends up being much much better than most off the shelf HT subwoofers, but not quite up to snuff with some of the long throw home audio subwoofers from Peerless, SEAS, TC, etc. That's why there's two of them. There is a 250 watt amplifier mounted in a "backpack" on the right hand subwoofer enclosure, so it doesn't shrink the cabinet space, and the two woofers are both DVC, running a series/parallel configuration for a 4 ohm load. And those things rumble! The last thing I need in that room is more bass; its already just ridiculous. And again, cost me very little.
Hell of a project; I'm glad its done. Sometime in the near future, I'm going to be doing some rear speakers... I'm considering the HiVi driver "Overnight Sensation" build that is a cheap, popular small speaker in the DIY community. But for now, I need some rest