Synergy style horns

[NBPk402]

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

[NBPk402]

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.

[NBPk402]

more pics

[NBPk402]

more pics

[NBPk402]

Pics of the construction so far...

Basic box 40" wide x 27 1/2" tall, 26" deep.

Synergy style horns

Synergy style horns

Sides of horn being mocked up:

Synergy style horns

Synergy style horns

Ports for horn.

Synergy style horns

[NBPk402]

View of the sides with woofers installed,and compression driver mount.

Synergy style horns

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

Synergy style horns

[NBPk402]

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.

Synergy style horns

[NBPk402]

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[NBPk402]

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[NBPk402]

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[NBPk402]

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[AVSMike]

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.

[NBPk402]

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

[AVSMike]

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?

[NBPk402]

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.