I just wanted to share a little project I've been working on the last couple weeks. I am building a simple MT, 2 way speaker. The design is called the Modula MT, it was designed by a guy over at the HT Guide forums. It is designed around the Dayton Audio Reference Series mid and Seas 27TDFC tweeter. There are other designs for different tweeters, like the Dayton Reference Series tweeter. I went with the Seas because it is a soft dome instead of metal.
This is my first speaker build (I've built subs before) and I probably should have done something a little easier, but I wanted to build something a little more exciting than a standard box speaker. I also wanted a floorstanding speaker so that I didn't have to mess with stands. So I figured I'd try my hand at a curved sided cabinet, kind of like the Sonus Faber Cremona series. I had a friend of mine model the shape of the enclosure in CAD software, then I just printed it out, traced it to a piece of MDF, and cut it out with a jigsaw. Once it was sanded to a smooth looking curve I could use that piece as a template to cut the remaing braces using my router with a flush trim bit. Using a flush trim bit ensures that all the braces are the exact same size and shape.
After cutting all the braces I cut some dados in the inner baffles for the braces to slide into. the inner baffles are 1/2" MDF and are used to hold the brace skeleton together. Once the braces and inner baffles are glued together I can apply the curved sides. I will be using layers of 1/8" hardboard (which is like a pegboard material) for the sides. I would have used bendable plywood (wiggle wood) but it was more expensive than I wanted to sink into this project. Hardboard is MUCH cheaper. It is pretty dense and flexible enough to use.
Once all the sides are on I will add another 1/2" outer baffle to the front and back. I am going to try applying the first layer of side pieces tonight.
I've attached a few pics but there are a few more in the link below.