Investigating different methods for loudspeaker enclosures
The construction of the enclosure is very important to the final success of the loudspeaker. Even very small mistakes in the construction process; such as ill-fitting panels, can cause disastrous effects to the sound, as the vibration of air around poor joints etc. causes unwanted noise.
For the panels of the baffle, the MDF will need to be cut using some sort of saw. Sharp edges will be needed to ensure a perfect fit. Once assembled these edges can be filed down to prevent them being hazardous. Holes of suitable diameters will need to be bored in the front baffle for the drive units. The drive units can be mounted from the inside of the baffle to form a neater appearance using nuts and bolts.
The joining of the MDF to form the baffle poses a difficult problem. The most sturdy, quality product would be achieved by dove-tailing the joints. However this would be very time consuming; especially for a floorstanding model. Experience also shows that this method is unsuitable, as far as I can see no product on the existing market shows any signs of the use of dove-tail joints. The joining techniques would have been one thing I would have liked to find out from my letters to existing manufacturers, but the limited information that those who replied gave did not include such information. Dismantling an older pair of speakers reveals that the joining was done through use of pins and glue. A more appropriate method may be a mitre joint, a half-lap joint or may be a comb (finger) joint. These joints would provide the strength required; and be easy to manufacture; especially in quantity, with a decent finish.