My Build - Paul Car...
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My Build - Paul Carmody Speedsters - Hickory And Walnut  

Phil G
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Joined: 2 years ago
Posts: 11
Topic starter  

Here is the project I worked on while sheltering in place. 

Lets take a look at the finished product then I'll show you how it was done.

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 I do my wood working outdoors and it was raining when I received the kit so I started by assembling the crossovers.

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 Parts laid out and ready to begin!  I purchased the circuit boards because I thought it was a cleaner solution.  The kit came from Meniscus Audio and I upgraded the capacitors based on their recommendation.  After listening to the speakers, I can honestly say "I'm glad I did."

Clear weather - time to cut some wood!

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In my eagerness to get started, I didn't take pictures of the table saw work.  I was cutting the biscuit slots when I remembered the camera. 

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From my previous build (DINAS) I learned the importance of keeping all the box components oriented in the manner the biscuit slots were cut and they will be assembled.  Dry fit looks good - Time for glue!

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Glued and Clamped! 

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I cut the front baffle oversize and used a trim bit in the router to get an exact fit.

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Using the Jasper jig for the speaker cutouts.  This didn't go well (I botched it badly) and the baffles were noticeably different.  Unacceptable!  I threw them out and started over.  

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New baffle clamped in place.  Rounding over all edges with a 3/4" round over bit.  The bit is new but it left some burn marks which were easy to sand out.  Important to always have a clamp on the baffle when repositioning the box so you can continue routing.

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Lots of sanding later and things are looking good!

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I should have cut the baffles before applying the finish but I really like the transformation that takes place when the finish is applied and I couldn't resist!  I didn't have enough hickory so I pieced together ash and walnut for the back.

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This time I'm making sure the baffles match.  I made a pattern out of 1/2" MDF, secured the baffle to the pattern with foam tape and cut them with a pattern bit.  Same for the back.  I cut the pattern in half because it was too awkward to use on the back.  Make sure to wait for your router to completely stop before removing from a small diameter hole - I didn't and the bit chewed up the port on one of the boxes and ruined the pattern.  It was not so bad the box was unusable but it did cause a moment of panic.


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Test fitting the drivers - ohhh they look nice!

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Crossover installed.  You can see where I caulked around the port tube.  This is the one the router chewed up and I felt it needed a little extra support.

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I'm listening to them now -  they sound fantastic!  Powered by PS Audio Sprout with a Sony CD player.

Illustrious Member Admin
Joined: 3 years ago
Posts: 1185

@phil-g You killed it!  I love everything about them.  Especially appreciated the biscuit joints you used.  Nice solid build!


Phil G
Active Member Registered
Joined: 2 years ago
Posts: 11
Topic starter  

Thanks Nick.  The nice thing about building the speedsters is there are a lot of build threads.  I took my inspiration from this one...

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