Frugel Horn Lite - Frugal-Horn
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Drawings/Contents (provisional) i0/ Intro i1/ Pictures i2/ Notes FHL-0/ Plan 12mm FHL-1/ Side pattern creation FHL-3/ Side template (metric 12mm) FHL-4/ Side template (imperial 1/2”) D-0/ Damping D-1/ full size side felt template (12mm) D-2/ felt cut plan (12mm) C-0/ 5x5 12mm cut plcan C-1/ 4x8 12mm cut plan please email me <david@planet10-hifi .com> with corrections & suggestions to make this document more useful In late 2006 – ’07 a small group of enthusiasts collaborated to develop a compact , inexpensive corner-horn design for the DIY community. This project became the very successful Frugel-Horn, which even spawned an extremely expensive commercial adaptation. The Frugel-horn Mk3 [FH3] , a ground-up new design, followed and has been a very successful design with many 100s of builds. The FH3 led to many requests for a similar cabinet for larger drivers. That led to the Frugel-Horn XL [FHxl]. Now we introduce the Frugel-Horn Lite, a smaller horn for 3” drivers. Initially designed and tested for the Fostex FF85wk, it has been simmed for other drivers and like the FH3 and FHxl should find itself suitable for a wide range of drivers. Currently vetted drivers: Fostex FF85wk, Fountek FR88ex, FR89ex, FE85, Vifa TC9FD, AuraSound NS3, most 3” TB units (some with the huge motors may have some clearance issues), Mark Audio Alpair 6.2 M & P (will require a supraBaffle to fit big bezel), ScanSpeak 10F Use of deflectors & supraBaffles yet to be explored. Note: any commerical entity intent on manufacturing complete speakers or flat-paks for resale will need to follow the guidelines on the Frugal-Horn site + make a suitable donation to diyAudio.com: www.frugal-horn.com/use.html This project’ s contributors: DIYers who went ahead, assisted in beta testing, offered comment and suggestions diyAudio: host for interactive discussion threads Scott Lindgren <http://www.wodendesign.com/> design & documentation Ron Clarke: the curved mouth Chris Bobiak: Original test builds & drawing contribution David Dlugos: drawings & testing. Your name here: you can help with FAQ, assembly diagrams & pictures, photo gallery. Probably more. Local cottage industry to make & distribute flat-paks encouraged , please contact Dave (david@planet10-hifi .com) Frugel - Horn Lite 29-june-2015 | © 2010-2015 Frugal-Horn.com Major Sponsors & Cheerleaders
Transcript of Frugel Horn Lite - Frugal-Horn
Drawings/Contents (provisional)
i0/ Introi1/ Picturesi2/ Notes
FHL-0/ Plan 12mmFHL-1/ Side pattern creationFHL-3/ Side template (metric 12mm)FHL-4/ Side template (imperial 1/2”)
D-0/ DampingD-1/ full size side felt template (12mm)D-2/ felt cut plan (12mm)
C-0/ 5x5 12mm cut plcanC-1/ 4x8 12mm cut plan
please email me <david@planet10-hifi .com> with corrections & suggestions to make this document more useful
In late 2006 – ’07 a small group of enthusiasts collaborated to develop a compact, inexpensive corner-horn design for the DIY community. This project became the very successful Frugel-Horn, which even spawned an extremely expensive commercial adaptation.
The Frugel-horn Mk3 [FH3] , a ground-up new design, followed and has been a very successful design with many 100s of builds.
The FH3 led to many requests for a similar cabinet for larger drivers. That led to the Frugel-Horn XL [FHxl].
Now we introduce the Frugel-Horn Lite, a smaller horn for 3” drivers. Initially designed and tested for the Fostex FF85wk, it has been simmed for other drivers and like the FH3 and FHxl should find itself suitable for a wide range of drivers.
Currently vetted drivers: Fostex FF85wk, Fountek FR88ex, FR89ex, FE85, Vifa TC9FD, AuraSound NS3, most 3” TB units (some with the huge motors may have some clearance issues), Mark Audio Alpair 6.2 M & P (will require a supraBaffle to fit big bezel), ScanSpeak 10F
Use of deflectors & supraBaffles yet to be explored.
Note: any commerical entity intent on manufacturing complete speakers or flat-paks for resale will need to follow the guidelines on the Frugal-Horn site + make a suitable donation to diyAudio.com: www.frugal-horn.com/use.html
This project’s contributors:DIYers who went ahead, assisted in beta testing, offered comment and suggestionsdiyAudio: host for interactive discussion threadsScott Lindgren <http://www.wodendesign.com/> design & documentationRon Clarke: the curved mouthChris Bobiak: Original test builds & drawing contributionDavid Dlugos: drawings & testing.
Your name here: you can help with FAQ, assembly diagrams & pictures, photo gallery. Probably more.
Local cottage industry to make & distribute flat-paks encouraged, please contact Dave (david@planet10-hifi .com)
Frugel-Horn Lite29-june-2015 | © 2010-2015 Frugal-Horn.com
Major Sponsors& Cheerleaders
Comments & tips pulled form forum posts ———————————————————————————————
As several of the internal angles are not as convenient as the 5° common throughout the FH3, a magnetic angle gauge is very helpful. If you don’t already possess one, it’s a very good investment.
Not described in the drawing is the small tapered gluing block near apex of line (i.e near bottom joint) For the angled (scarf) joint of bottom of back panel and internal divider, (item #3 opposite) a tenoning jig on table saw works perfectly. Using the magnetic gauge, set the blade to required angle and clamp back panel at 90°.
If a tenoning jig is not available for above step, the tapered wedge cut at 7° ensures a tight joint and increased glue surface area.
Notes16-june-2015
Notes ———————————————————————————————
0/ quality multi-ply/plywood is recommended. In general, void free, the greater number of plies the better1/ reference build is 12mm plywood2/ if MDF or particle board used a minimum panel thickness of 18mm, good multi-ply minimum 12mm3/ the most difficult detail in the build is the joint at the bottom of back, inside divider. 4/ A full height rear deflector based on that shown in the Frugel-Horn Mk1 document can be added
Notes:
1/ drawn with 12mm material2/ Fostex FF85wk is the default driver but these have been checked & should work: Fountek FR88ex, FR89ex, FE85 Vifa TC9FD AuraSound NS3 most 3” TB units (some with the huge motors may have some clearance issues) Alpair 6.2 M & P (will require a supraBaffle to fit big bezel) ScanSpeak 10F
1335 mm radius (52 9/16”)
737[29]
114[4 1/2]
127[5]
57[2 1/4]
32[1 1/4]
57[2 1/4]
762[30]
368[14 1/2]
381[15]
102[4]
126[4 15/16]
66[2 5/8]
57[2 1/4]
152[5 31/32]
5°
5°
Frugel-Horn Lite 0v9sheet FHL1-0 – 12mm Planfor FF85wkdesigned by S Lindgren | drawn by dld16-June-2015 © 2010-15 Frugal-Horn .com
45° cut on the endof end piece. Round
over top edge joinwith back partition
using sand paperafter assembly. This
point is subject tohigh pressures, glue
very well.
708.7[27 29/32]
647.7[25 1/2]
764.5[30 3/32]
140.4[5 17/32]
369.3[14 17/32]
Frugel-Horn Lite 0v9sheet FHL1 – 12mm detaildesigned by S Lindgren | drawn by dld16-june-2015© 2010-2015 Frugal-Horn.com
back internal bottom
top
baffle
5°
5.0°
5.0°
5.5°
5°
5°
45°
Notes:
1/ all parts 102 mm (4”) wide, 12mm thick
766[30 5/32]
56[2 7/32]
To fabricating a side panel template by hand, the curve can easily be drawn using a narrow flexible board (1/4” MDF works great) and the 4 points as dimensioned.
Mark points A,B (chord ends), C (chord centre line) and D (segment height) on the work-piece. Use a square to draw a perpendicular line (C-D)
Clamp or screw a wood block straddling the centreline at D, clamp the flexible board to this block and each end of the chord ( A & B) then draw the curve.
Cut to the outside with jig or band saw, and carefully sand to line
383[15 3/32]
383[15 3/32]
A
B
C D
Frugel-Horn Lite 0v9sheet FHL-1 – curve chord & height
designed by S Lindgren | drawn by dld16-june-2015© 2010-2015 Frugal-Horn.com
1/2” (12mm) cotton or wool felt
increasing density as you approach the point. Take the equal density fluff on the right and squeeze it into the point (~18g = 0.61 oz )
walls lined around driver to minimize reflections
this is the area subject to additional poly-fluff damping, depends on driver
see notes page ix for driver-by-driver
(at 1/2 lb/ft^3 this volume would need ~24g (0.8 oz) of fluff)
poly-fluff (BAF, acoustistuff, pillow stuffing -- different colours represent different “zones” to add stuffing to -- different material will have different characteristics) .
Frugel-Horn Lite 0v8sheet D-0 – damping plan
designed by S Lindgren | drawn by dld29-june-2015© 2010-2015 Frugal-Horn.com
Frugel-Horn Lite 0v9Sheet C-0 – 5x5 12mm cut sheet
drawn by dld / 16-june-2015© 2010-15 Frugal-Horn .com
Notes:1/ 5mm kerf & trim allowance
139[5 15/32]
369[14 17/32]
765[30 3/32]
102[4]
761[29 15/16]
381[15]
baff
le
bott
omto
pin
tern
al
back
bott
omto
pin
tern
al
baff
leba
ck
648[25 1/2]
708[27 27/32]
102[4]
top
Frugel-Horn Lite 0v9Sheet C-1 – 4x8 12mm cut sheet
drawn by dld / 16-june-2015© 2010-15 Frugal-Horn .com
Notes:1/ 5mm kerf & trim allowance
138[5 7/16]
368[14 1/2]
765[30 3/32]
102[4]
761[29 15/16]
381[15]
baff
le
bott
omto
pin
tern
al
back
bott
omin
tern
al
baff
leba
ck
649[25 17/32]
708[27 27/32]
102[4]
