Project Time: 8-20 hours
Project Complexity: Professional
Project Cost: Over $1000

Driver Selection
The purpose of this design was a dual-woofer loudspeaker with high sensitivity and improved mid range response. A dual woofer loudspeaker using the Dayton 6-1/2″ shielded woofer, Dayton 5-1/4″ shielded mid woofer, and Dayton 1-1/8″ silk dome tweeter. These drivers are among the “best bang for the buck” in low price loudspeaker drivers. These speakers provide quality sound at reasonable price. Project Edit: It appears that this project actually used the Vifa PL27TG-35-06 (looking at the crossover diagram). This tweeter has been discontinued and the Vifa D27TG-35-06 1″ Silk Dome Tweeter has been substituted into the project.

Enclosure Design
I choose to build the cabinets out of 3/4 inch oak plywood (the next ones I build will be out of 3/4 inch MDF particle board and covered with veneer). The finish is an application of MinWax light oak stain and then two applications of MinWax Polyurethane Satin finish The platforms are made from MDF particle board glued together to make a 1 1/2 inch thick base, I made my own spikes out of 1/2 inch x 3inch bolts, these allow me to level the tower and makes them very stable. The finish on the platforms is black lacquer.

Amplifier/Crossover Configuration
My next problem was crossovers; my new good friend Curt C. guided me through the speaker design, letting me decide what I wanted to build and then designed the crossovers. Crossover Construction and Installation The crossovers are mounted on 1/8 inch white board, I soldered all connections and used wire ties and hot glue to hold the components solid on the board.

Conclusion
Building a project of this magnitude was very rewarding, but at the same time it was very stressful from the fear that the money invested would turnout a speaker that didn’t work or sound good. Needless to say these speakers brought a big smile on my face when I had them all hooked up and running. Even my audiophile friend was surprised at the quality of sound my system produces. I would describe the sound at crisp and clean, slightly bright but not too harsh and very detailed. All speakers sound the same and produce an excellent sound stage and surround sound. I would put these speakers up against a $2000 speaker any day and my approximate cost for all five speakers is only at $1100.00. Of course I didn’t add in the hours of labor, but when you’re doing something you enjoy– who cares. I contribute my success to the excellent designed crossovers by Curt C. and baffle board layout. And would like to thank all my friends for all their help.

Project Parts List