Crossover Board and Component Placement Recommendations

[ma7rix13]

Hello, trying my first DIY speaker build

Putting together my ZMV5 crossover and am running into some questions:

1) Where and how do you guys suggest mounting this crossover, its pretty big compared to the box and I don't want to mount it where it interferes with the speakers. In addition, I am trying not to use metal screws as they might change the inductance, do you guys use nylon screws to mount the crossovers and components or hot glue?

2) What would be the recommended layout of the crossover itself so the EM field does not mess up the other inductors.

Thanks, any help would be greatly appreciated.

Paul

 

[TLS Guy]

Hello, trying my first DIY speaker build

Putting together my ZMV5 crossover and am running into some questions:

1) Where and how do you guys suggest mounting this crossover, its pretty big compared to the box and I don't want to mount it where it interferes with the speakers. In addition, I am trying not to use metal screws as they might change the inductance, do you guys use nylon screws to mount the crossovers and components or hot glue?

2) What would be the recommended layout of the crossover itself so the EM field does not mess up the other inductors.

Thanks, any help would be greatly appreciated.

Paul

I mount with brass bolts nuts and washers. I try to mount the crossover behind the woofer or on a brace behind the woofer.

 

[basspig]

Put Loktite on all the nuts so they don't come loose months later.

 

[Swerd]

1) Where and how do you guys suggest mounting this crossover, its pretty big compared to the box and I don't want to mount it where it interferes with the speakers. In addition, I am trying not to use metal screws as they might change the inductance, do you guys use nylon screws to mount the crossovers and components or hot glue?

2) What would be the recommended layout of the crossover itself so the EM field does not mess up the other inductors.

Caps and resistors can go anywhere. For arranging inductor coils, follow the guide lines in this link, especially the diagram near the bottom of the page. 10 cm is about 4 inches. Also remember to apply those same guide lines for the woofer magnet and the inductor coils on your crossover.

Another very useful link, describes a general thought process to use when going from a schematic diagram to a practical layout of a crossover board.

I use nylon cable ties to attach components to the board. Its fast and reversible. Like Zaph says, don't use steel screws to hold down that large laminated core inductor. I used to use hot melt glue but it has failed too often in the past, especially with heavier inductors. Other people use other stronger adhesives such as epoxy.

Because you have to drill holes in the board to use cable ties, I usually use masonite or plywood, ¼" or less in thickness. That also allows using two smaller boards. From your photos, it looks like the board you are trying to use is simply too large for the available space. Try using two smaller boards, one for the tweeter network and the other for the woofer.

I use brass screws or nuts & bolts to fasten the boards inside the cabinet. They are cheap and readily available. I used to try to glue them down, but if you use a strong enough glue, never try to remove them, and if you use hot melt glue, you’ll often have to reattach them.

 

[ma7rix13]

Thanks guys, did some research today and found this great write up on PE...

http://techtalk.parts-express.com/showthread.php?t=212179&highlight=ZMV5&page=6

I believe its exatcly what you are talking about with the cable ties...

Damn, I am obsessed, I have been doing 8 hours of straight speaker research at work...

 

[Swerd]

Thanks guys, did some research today and found this great write up on PE...

http://techtalk.parts-express.com/showthread.php?t=212179&highlight=ZMV5&page=6

I believe its exatcly what you are talking about with the cable ties...

Damn, I am obsessed, I have been doing 8 hours of straight speaker research at work...

Yes, that is exactly how I use cable ties. No waiting for messy glues to dry.

Thanks, that PE link was a fun read. Its always good to see how sloppy or compulsive other people are. Compared to that guy, I'm a real slob .

Don't let any of those elaborate details intimidate you if you think your methods are unworthy. There are dozens of ways to build a box, and most of them work pretty well.

You are clearly getting infected by this hobby. I saw in the photos of your nicely built cabinets, how you even caulked the seam between the inner cabinet wall and the interior brace. You can absolutely 100% guarantee that no air will ever leak through there . I know how easy it is to just caulk everything once you have the gun loaded with a freshly opened caulk tube.

Keep up with the good work. And please, take more photos.

 

[ma7rix13]

Yes, that is exactly how I use cable ties. No waiting for messy glues to dry.

Thanks, that PE link was a fun read. Its always good to see how sloppy or compulsive other people are. Compared to that guy, I'm a real slob .

Don't let any of those elaborate details intimidate you if you think your methods are unworthy. There are dozens of ways to build a box, and most of them work pretty well.

You are clearly getting infected by this hobby. I saw in the photos of your nicely built cabinets, how you even caulked the seam between the inner cabinet wall and the interior brace. You can absolutely 100% guarantee that no air will ever leak through there . I know how easy it is to just caulk everything once you have the gun loaded with a freshly opened caulk tube.

Keep up with the good work. And please, take more photos.

Yeah, as an engineer, its easy to see that those guys clearly "over engineered" for a $100 speaker. My requirements this build are, fast, cheap, reliable, great sounding speaker to see if I like the whole process. My next build I will probably be over engineering things with high cost components...

Update on the crossovers; was rummaging around the workshop and found some left over pegboard, it worked great to mount the crossover to, its light, cheap, and already has lots of holes to put cable ties through. I will have to post pics tonight (but for now, some other random pics), they do the job, although I'll admit its not that pretty...

Paul