In pic 2 it's steel 8\10, even my big horn are made from steel. the reason is costhere aluminum plate and bar are difficult to find and they sold at very high prices ( 40km the nearer shop, 8e \ kg ). I tried to weld a 6\10mm alu plate with oxy-acet and a special flux with criolite, i got the recipe in my manual, but ingredients are not easy to find. really expensive flux and delicate material, when flux is good quantity and quality it's a fraction of second and it makes huge holes, when flux is poor or not in quantity alu makes White oxide cover... I tried because i want to build to my 2 little bikes alu gas tank, the steel one ugly i made, not treated with tankerite or similar is making some rust.
As you say the different sections are not just for esthetics in my big horn, i made 2 horns loaded by one driver, in few words the big and long part cover from 100 to 350\400 hz and the small upper horn cover from 350 to up frequency. You're right! i choose steel and the "floating" Anchorage with silentblock to help them resonate more than a cement type horn. It was a gamble, i bet that above all in lower fq this can help, the mix steel + body shutz + cork gives good performance .
In this days i should receive a microphone for testing the speaker (ecm8000 behringer, with Scarlett 2i2 sound card and dcx 2496 processor), i hope i can do some good measures and adjust the system!
you're right about mixing different kind of speaker and horns, it's not so easy making passive crossovers, but it's not impossibile. With a bit of luck the differences in efficency can be solved using an L-pad resistor or a pot to match other speakers. The big problem in my opinion is the prices of components for making good passive xovers, if you want to make a first order filter bw type for a tweeter, a simple (but good) cap like mundorf makes excellent work with few bucks, but when you have to buy different huge inductors and capacitors for trying some lower (150 to 500hz) cuttoff fq the situation becomes hard, and even harder trying different order of xover... I thinked lot of time, but at the end i decided to buy an active crossover with 3 stereo channel. this dcx 2496 is cheap compared to other hi end filters, it's pro audio, but it sounds good and above all you can change type of filter, delay, cutoff, offset, eq and Others parameters in real time. cons you have to give it one amplifiers for each channel ... but it's not a big problem
now i have to go out, after i try to do a simple image of the flange. the last 2 pics alu plate welded with flux and not grinded. i think with some practice i can weld 1,5mm for gas tank
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here aluminum plate and bar are difficult to find and they sold at very high prices ( 40km the nearer shop, 8e \ kg ). I tried to weld a 6\10mm alu plate with oxy-acet and a special flux with criolite, i got the recipe in my manual, but ingredients are not easy to find. really expensive flux and delicate material, when flux is good quantity and quality it's a fraction of second and it makes huge holes, when flux is poor or not in quantity alu makes White oxide cover... I tried because i want to build to my 2 little bikes alu gas tank, the steel one ugly i made, not treated with tankerite or similar is making some rust.







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