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Notes on building horn enclosures from wood laminates
by J. Gaspar Rivera
I've heard and read of bending plywood, but I've never worked with it. I also lack the necessary technical information to recommend it. I'll say this, though, if you are experimenting, I guess it's OK to try it. On the other hand, if your aim is permanence and great sound, you should do those bends with veneers. I mean, once you seal a speaker box, you can't change the interior! Also, since you have a reputation to maintain in the horn-speaker world, I suggest that you do it the best way possible and that means veneers.
I'll tell you why I'm skeptical. One of the problems with manufactured plywoods is the glue. Everyone uses cheap glues to lower cost. However, if you want something that will last, you must use a waterproof glue, which is more expensive. The reason for this is that humidity weakens the bond between the glue and the wood ( a very common problems). So if you want permanence, do those bends with wood veneers and a strong glue. Glues? Hey, I go for the best: Epoxy (West System). You can also use polyurethanes (Gorilla glue), or you can try Titebond II, a new waterproof glue from Franklin.
For 1/20", 1/16", 1/8" veneers try this outfit and get their informative catalog. This info is important because these veneer sizes are very, very hard to find. Nowadays, everyone is doing 1/32" veneers. Certainly Wood. (716) 655-0206 11753 Big Tree Road, East Aurora, NY 14052.
Jericho Horn by Eddie Van Veldhuizen, a scientist from Holland. It has some nice construction pictures. Plus I like the way he rounded all the corners to improve the sound of the Jericho Horn (Fostex FE-208 Sigma driver). As you will see from his Jericho Horn pictures, he has actually redesigned those speakers. First, he built the standard version (like Ulrich Haumann), but he disliked the midrange coloration he got. So he did his own version with thicker walls (24mm) made from birch plywood, and curves at the bends (rather elegant, IMHO). As I've said before, the curves DO improve the sound of a folded horn. That's why I like Van Veldhuizen's Jerichos!
The Hedlund Horn by Miroslav Ivanek uses real wood veneers.
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