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Synergy style horns

ellisr63

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Synergy style horns
« on: November 03, 2016, 03:22:59 PM »
I have been wanting to make a full range horn loaded speaker for a while...so today I picked up some 2' x 2' plywood to do some testing. I will be starting with some 2' x 2' plywood horns, and then adding some woofers to them after running REW on them. If they sound as good as I have heard they do, I will then make another one that is bigger. Luckily I have 3 spare EV DH1As to use for 3 new Synergy horns with multiple 15" woofers, and some friends who have helped me get this far. I will post pics up as I progress.

Update:
I decided to just up the size, and go to what I really wanted to do... Go larger :)

The new Synergy horns will have a horn approximately the same size as a Klipsch K-402, but it will not have a flare. This will give me a 40" wide horn that is 26" high, and 26" deep (total depth includes the Ev DH1A driver).


Cost Breakdown:
Eminence Kappa-15C... $109 each (2 required per speaker)
EV DH1A driver... $ I already have 3 spares (enough to do all 3 front speakers), but if I was to buy them used it would be around $100 each
Speaker connectors (2 sets per speaker)...$unknown as I had them laying around already
3 sheets 3/4 MDF... $150
« Last Edit: November 18, 2016, 04:53:01 PM by ellisr63 »
Yamaha CX-A5100, (3) diy synergy horn 2 ways,, 4 JBL 8340As, 4 JBL 8320s, PS3, XBoxOne, Monoprice speaker wire, and XLR cables, Redmere HDMI cables, Monster HTPS7000, 2 Furman filters, 2 DTS-10 subs, Panasonic AE8000, SeymourAV 195" diagonal scope screen, Panamorph UH-480, Darbee Darcet, Yamaha P7000s, diy 14 channel Ice PowerPoint amp

ellisr63

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Re: Synergy style horns
« Reply #1 on: November 03, 2016, 03:25:54 PM »
Here is what I have so far... Does this look right? Suggestions?
Here is a link to the Synercalc, Hornresp file.

My friend Chris is helping me (doing most of the work), and last night he found an error. Here is what it looks like after the error was fixed(last image). The red line on the amp gain is the new setting (what was changed is in the BI block...it was changed from 66.28 to 6.63). All of this is for a prototype 2' x2' x2' Synergy style horn. If this works out good... I am thinking of a horn with a 3' or larger mouth. What I have been told is this should go down to 40Hz without any problem... Pretty good for a 2 way horn IMO.
Yamaha CX-A5100, (3) diy synergy horn 2 ways,, 4 JBL 8340As, 4 JBL 8320s, PS3, XBoxOne, Monoprice speaker wire, and XLR cables, Redmere HDMI cables, Monster HTPS7000, 2 Furman filters, 2 DTS-10 subs, Panasonic AE8000, SeymourAV 195" diagonal scope screen, Panamorph UH-480, Darbee Darcet, Yamaha P7000s, diy 14 channel Ice PowerPoint amp

ellisr63

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Re: Synergy style horns
« Reply #2 on: November 03, 2016, 03:26:14 PM »
more pics
« Last Edit: November 03, 2016, 03:32:06 PM by ellisr63 »
Yamaha CX-A5100, (3) diy synergy horn 2 ways,, 4 JBL 8340As, 4 JBL 8320s, PS3, XBoxOne, Monoprice speaker wire, and XLR cables, Redmere HDMI cables, Monster HTPS7000, 2 Furman filters, 2 DTS-10 subs, Panasonic AE8000, SeymourAV 195" diagonal scope screen, Panamorph UH-480, Darbee Darcet, Yamaha P7000s, diy 14 channel Ice PowerPoint amp

ellisr63

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  • Surfing in the Home Theater
Re: Synergy style horns
« Reply #3 on: November 03, 2016, 03:26:28 PM »
more pics
« Last Edit: November 03, 2016, 03:32:55 PM by ellisr63 »
Yamaha CX-A5100, (3) diy synergy horn 2 ways,, 4 JBL 8340As, 4 JBL 8320s, PS3, XBoxOne, Monoprice speaker wire, and XLR cables, Redmere HDMI cables, Monster HTPS7000, 2 Furman filters, 2 DTS-10 subs, Panasonic AE8000, SeymourAV 195" diagonal scope screen, Panamorph UH-480, Darbee Darcet, Yamaha P7000s, diy 14 channel Ice PowerPoint amp

ellisr63

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Re: Synergy style horns
« Reply #4 on: November 03, 2016, 03:26:43 PM »
Pics of the construction so far...

Basic box 40" wide x 27 1/2" tall, 26" deep.
http://i1065.photobucket.com/albums/u393/ellisr63/Synergy%20build/Our%20Synergy%20speaker%20build/20161127_102456_zpsqnt9wftt.jpg
Synergy style horns


http://i1065.photobucket.com/albums/u393/ellisr63/Synergy%20build/Our%20Synergy%20speaker%20build/20161127_102504_zpspzpi8rvm.jpg
Synergy style horns


Sides of horn being mocked up:
http://i1065.photobucket.com/albums/u393/ellisr63/Synergy%20build/Our%20Synergy%20speaker%20build/20161127_120950_zpsfr844z2x.jpg
Synergy style horns


http://i1065.photobucket.com/albums/u393/ellisr63/Synergy%20build/Our%20Synergy%20speaker%20build/20161127_121003_zps40xmn3n4.jpg
Synergy style horns


Ports for horn.
http://i1065.photobucket.com/albums/u393/ellisr63/Synergy%20build/Our%20Synergy%20speaker%20build/20161127_131931_zpsx93a6aq6.jpg
Synergy style horns
« Last Edit: November 27, 2016, 04:13:48 PM by ellisr63 »
Yamaha CX-A5100, (3) diy synergy horn 2 ways,, 4 JBL 8340As, 4 JBL 8320s, PS3, XBoxOne, Monoprice speaker wire, and XLR cables, Redmere HDMI cables, Monster HTPS7000, 2 Furman filters, 2 DTS-10 subs, Panasonic AE8000, SeymourAV 195" diagonal scope screen, Panamorph UH-480, Darbee Darcet, Yamaha P7000s, diy 14 channel Ice PowerPoint amp

ellisr63

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  • Surfing in the Home Theater
Re: Synergy style horns
« Reply #5 on: November 03, 2016, 03:27:01 PM »
View of the sides with woofers installed,and compression driver mount.

http://i1065.photobucket.com/albums/u393/ellisr63/Synergy%20build/Our%20Synergy%20speaker%20build/20161127_151508_zpsnuybvf0y.jpg
Synergy style horns


Front view of horn (we still need to trim off the horn sides which extend beyond the front of the cabinet).

http://i1065.photobucket.com/albums/u393/ellisr63/Synergy%20build/Our%20Synergy%20speaker%20build/20161127_151530_zpsif0eszgm.jpg
Synergy style horns


« Last Edit: November 27, 2016, 04:17:28 PM by ellisr63 »
Yamaha CX-A5100, (3) diy synergy horn 2 ways,, 4 JBL 8340As, 4 JBL 8320s, PS3, XBoxOne, Monoprice speaker wire, and XLR cables, Redmere HDMI cables, Monster HTPS7000, 2 Furman filters, 2 DTS-10 subs, Panasonic AE8000, SeymourAV 195" diagonal scope screen, Panamorph UH-480, Darbee Darcet, Yamaha P7000s, diy 14 channel Ice PowerPoint amp

ellisr63

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  • Surfing in the Home Theater
Re: Synergy style horns
« Reply #6 on: November 03, 2016, 03:33:15 PM »
Here is the internal woofer cavity with measurements... Hopefully we didn't space the ports to far out to clear the top and bottom angles of the horn... We will find out next weekend.

http://i1065.photobucket.com/albums/u393/ellisr63/Synergy%20build/Our%20Synergy%20speaker%20build/20161127_132213_zpsyn3ocrav.jpg
Synergy style horns
« Last Edit: November 28, 2016, 11:05:06 AM by ellisr63 »
Yamaha CX-A5100, (3) diy synergy horn 2 ways,, 4 JBL 8340As, 4 JBL 8320s, PS3, XBoxOne, Monoprice speaker wire, and XLR cables, Redmere HDMI cables, Monster HTPS7000, 2 Furman filters, 2 DTS-10 subs, Panasonic AE8000, SeymourAV 195" diagonal scope screen, Panamorph UH-480, Darbee Darcet, Yamaha P7000s, diy 14 channel Ice PowerPoint amp

ellisr63

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  • 467
  • Surfing in the Home Theater
Re: Synergy style horns
« Reply #7 on: November 03, 2016, 03:33:31 PM »
reserved
Yamaha CX-A5100, (3) diy synergy horn 2 ways,, 4 JBL 8340As, 4 JBL 8320s, PS3, XBoxOne, Monoprice speaker wire, and XLR cables, Redmere HDMI cables, Monster HTPS7000, 2 Furman filters, 2 DTS-10 subs, Panasonic AE8000, SeymourAV 195" diagonal scope screen, Panamorph UH-480, Darbee Darcet, Yamaha P7000s, diy 14 channel Ice PowerPoint amp

ellisr63

  • ***
  • 467
  • Surfing in the Home Theater
Re: Synergy style horns
« Reply #8 on: November 03, 2016, 03:33:46 PM »
reserved
Yamaha CX-A5100, (3) diy synergy horn 2 ways,, 4 JBL 8340As, 4 JBL 8320s, PS3, XBoxOne, Monoprice speaker wire, and XLR cables, Redmere HDMI cables, Monster HTPS7000, 2 Furman filters, 2 DTS-10 subs, Panasonic AE8000, SeymourAV 195" diagonal scope screen, Panamorph UH-480, Darbee Darcet, Yamaha P7000s, diy 14 channel Ice PowerPoint amp

ellisr63

  • ***
  • 467
  • Surfing in the Home Theater
Re: Synergy style horns
« Reply #9 on: November 03, 2016, 03:34:14 PM »
reserved
Yamaha CX-A5100, (3) diy synergy horn 2 ways,, 4 JBL 8340As, 4 JBL 8320s, PS3, XBoxOne, Monoprice speaker wire, and XLR cables, Redmere HDMI cables, Monster HTPS7000, 2 Furman filters, 2 DTS-10 subs, Panasonic AE8000, SeymourAV 195" diagonal scope screen, Panamorph UH-480, Darbee Darcet, Yamaha P7000s, diy 14 channel Ice PowerPoint amp

ellisr63

  • ***
  • 467
  • Surfing in the Home Theater
Re: Synergy style horns
« Reply #10 on: November 03, 2016, 03:34:31 PM »
reserved
Yamaha CX-A5100, (3) diy synergy horn 2 ways,, 4 JBL 8340As, 4 JBL 8320s, PS3, XBoxOne, Monoprice speaker wire, and XLR cables, Redmere HDMI cables, Monster HTPS7000, 2 Furman filters, 2 DTS-10 subs, Panasonic AE8000, SeymourAV 195" diagonal scope screen, Panamorph UH-480, Darbee Darcet, Yamaha P7000s, diy 14 channel Ice PowerPoint amp

Re: Synergy style horns
« Reply #11 on: November 04, 2016, 06:18:11 AM »
Looking forward to this. Synergy horns are one of the toughest speakers to design and build. Good luck with the design and am looking forward to your results. :)
Mike Garrett
AV Science Sales
585-671-2968
mike@avscience.com

JVC, Sony, Epson, Marantz, Denon, Yamaha, Onkyo, Stewart, Seymour, Screen Innovations, Screen Excellence, DNP, Carada, Da-Lite, Vutec, Triad, SVS, Martin Logan, Def Tech, RBH, M&K and many other brands.

ellisr63

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Re: Synergy style horns
« Reply #12 on: November 04, 2016, 05:15:50 PM »
Thanks Mike!

Today I picked my woofers... I went with the Kappa_15C. Since this is the first one I am building I only ordered 2 (2 per each horn required). Here is a link to the specs...http://www.eminence.com/pdf/Kappa_15C.pdf
Yamaha CX-A5100, (3) diy synergy horn 2 ways,, 4 JBL 8340As, 4 JBL 8320s, PS3, XBoxOne, Monoprice speaker wire, and XLR cables, Redmere HDMI cables, Monster HTPS7000, 2 Furman filters, 2 DTS-10 subs, Panasonic AE8000, SeymourAV 195" diagonal scope screen, Panamorph UH-480, Darbee Darcet, Yamaha P7000s, diy 14 channel Ice PowerPoint amp

Re: Synergy style horns
« Reply #13 on: November 05, 2016, 02:56:31 PM »
Thanks Mike!

Today I picked my woofers... I went with the Kappa_15C. Since this is the first one I am building I only ordered 2 (2 per each horn required). Here is a link to the specs...http://www.eminence.com/pdf/Kappa_15C.pdf

How high will these play?
Mike Garrett
AV Science Sales
585-671-2968
mike@avscience.com

JVC, Sony, Epson, Marantz, Denon, Yamaha, Onkyo, Stewart, Seymour, Screen Innovations, Screen Excellence, DNP, Carada, Da-Lite, Vutec, Triad, SVS, Martin Logan, Def Tech, RBH, M&K and many other brands.

ellisr63

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  • 467
  • Surfing in the Home Theater
Re: Synergy style horns
« Reply #14 on: November 05, 2016, 03:36:48 PM »
How high will these play?
Are you talking about frequency? We are porting them for a 400-500Hz crossover, but they will play much higher in frequency.
Yamaha CX-A5100, (3) diy synergy horn 2 ways,, 4 JBL 8340As, 4 JBL 8320s, PS3, XBoxOne, Monoprice speaker wire, and XLR cables, Redmere HDMI cables, Monster HTPS7000, 2 Furman filters, 2 DTS-10 subs, Panasonic AE8000, SeymourAV 195" diagonal scope screen, Panamorph UH-480, Darbee Darcet, Yamaha P7000s, diy 14 channel Ice PowerPoint amp