Saturday, March 1, 2025

Back To Horns... Building DRC FrugalHorn Mk3s ~ Bandsaw Chord Cuts & MA Pluvia 7.2HD Drivers 28Feb25

The FrugalHorn Mk3 (FH3)... is a tapped (driver placed somewhere along the line of horn taper; on FH3, that's very early) hypex (hyperbolic exponential ~ meaning the flare of the horn increases monotonically and yields a smooth bass transition) corner-horn (where you put it in a room) with an internal choke serving for low pass filtering. It was born from 2005-2007 DIY enthusiasts seeking to design an easy to build (more later) corner horn... let's say the primary designer was Lindgren and I used base drawings from DLugos, but many from the DIY community (diyAudio.com) were involved, at least in stuffing and testing. That team has done all the acoustical physics math and tons of testing ~ I'm adopting the gen 3 variant directly and will just be the craftsman, listener, and tweaker. The designers don't release hornresp or other math models and I can't get the final segment of the horn (with the curved mouth) to render correctly in hornresp, so I'm flying a bit with faith. The design is very successful and lauded for accommodating a variety of drivers with just some damping changes and room placement adjustments. There are even $2K commercial versions as well as $750 "flat packs." I haven't built a horn since the original DRC BLHs in 2020. What's not to like? I have 2 more Mark Audio Pluvia 7.2HD drivers (~$50 each) for the initial buildout, expect 1 sheet of 15mm Baltic birch for $90, $40 binding posts, and I'll use leftover damping material (or a Target pillow).

Cutting Wood... The first task was cutting a tight layout from a 5'x5' piece of 15mmm Baltic birch. Given the tricky nature of the long side chord cuts and some other angles I first asked Matt @ CO Lumber to do all the cuts, but the price was way too high @ ~$450. I understand the many setups but golly. A friend with access to CNC offered cuts too but that didn't pan out I guess. So, within the viable pricing window, it was possible to purchase a home WEN bandsaw and do the cuts myself! I also bought 2 additional inexpensive tool benches for the WEN benchtop stuff in Silverthorne. With a new saw (mounted on a bench, as I did with the WEN drill press) and a new cut sheet, I first made some gross cuts in COS in order to get the pieces in the car with the doors closed... I did that with a rough wall powered jigsaw to the "big dotted green" cuts on the sheet... the baffles, bottoms, and tops had already been sliced off to even just get the plywood home from CO Lumber - with bungee chords on one door. Make no mistake, this cut sheet is challenging as precious little is square at the end of the day ~ keep your wits.

I got all the new stands, tools, and gross-cut parts to Summit ~ Crusher Too was packed to the gills. I made additional "gross cuts" between the 3 abutting side pieces with a corded 7.25" rotary saw, and at other times when the table saw rip fence was too close to accommodate a larger width.

The bandsaw was essential. I made front, top, and bottom cuts with the rotary saw, or the table saw when 90°, but the long chord cuts were made on the new bandsaw with two pieces (sides) clamped together. I used a bendy board to score a simple chord line... this curve is actually important in restoring low freq sound waves to spherical as they exit the back. Sure I needed to sand the chord too after cutting it but I had "drill bits" with floppy sandpaper on 'em for the occasion.
The parts are all cut now, but for the driver holes and some router work. Whew... this was not an "easy" day (weird angles and many cuts). When done after a day on the wood tools my back was talking to me... I closed with a fine Roam DDH Nelson from ORB, my Feb can club selection, and a spa ride in the snow.

I dry fit each speaker ~ all good. All the end angles have been cut and the driver holes have been cut and eased on the inside using a 45° bit in my router. All the parts are ready. My table saw angle adjustment is gross so I bought this keen tool to offer greater accuracy. A new inclinometer was used to assure end-angles were righteous... it's magnetized and stuck right to the blade after zeroing on the bed. The supra-baffles got eased driver holes and angle cut edges, for smoother transition from 2pi space. All the parts are ready for a glue fest tomorrow. I will first assemble a non-supra-baffle variant and measure it. I "know" there may be baffle diffraction step (BDS) issues, but I want a baseline before acoustically adjusting performance ~ I can always combat BDS loss with some miniDSP tweaks anyway.


Let The Adhesion And Stuffing Begin... I began gluing the FrugalHorns together on one side first ~ they need to be left open in order to add damping materials. Assembly was pretty easy (as compared to cutting) and after glue dried overnight I began lining with 1/2" damping felt, installing the binding posts, and stuffing in key areas. I didn't have enough polyfluff from prior builds so I bought a $4 pillow at Target ~ DIY baby. The FH3 cabinets are assembled! It's time to load the Pluvias and do some initial measurement and listening.

Initial Listen & Measure Of DRC FH3s... I did the bulk of needed raw sanding already and will do finishing later in warmer weather. As before with MA Pluvia metal cone drivers, I ran them in for 32hrs straight before measuring... they'll keep running as I think I really need 3 days. I don't really have permanent or even good corner locations for these in Summit but chose to set up in the Nest Study with its cathedral ceiling and somewhat available corners, to first listen and measure them. Whoa... even just driven by a simple T-Amp, this corner horn bass sound rocks with the MAP7.2HDs... very good. There may be better drivers with more rigid baskets or expensive cone designs or surrounds; heck, I've used 'em. But, make no mistakes, Mark Audio's range is killer in sound and value.

I quickly went to guns to measure the FH3s using my normal miniDSP mic 1 and REW. My listening position in COS will be at ~15' so I mimicked that here (I know, the room will change everything but this space is mid-volume as in COS); I closed the blinds. I confirmed what I heard, that the bass response of these new corner horns is very fine for a single tiny driver (BTW ~ I used 30g of fluff in both the trap and the throat... seems right for the MAP7.2HD. The dip 3KHz - 10KHz might yet be the unfolding of the driver... more later but I hear it and don't like it. Still, remarkably solid from 70Hz - 23KHz, naked with a bad amp: I love horns... more later.

Sidesaddle... It's noticeable to observers (both of them), I constrain my builds to efficient, full-range, single dynamic driver variants of speakers... the FH3s are the latest speaker of this ilk I've built. Why do I do this? ~ That's a topic for another post, but one reason is that constraints help me dive deeper in understanding and allow me to more easily achieve perfection/selection in a narrower category. I may miss a few things sure, but within class I can crush it. There's more 'cause single full range driver systems, in killer accompanying acoustical cabinets have efficiency, coherency, and dynamism galore.

Black Ice Amplification... As a final Nest test for the FH3s, I reallocated the sweet Black Ice FX10H tube amp from the Nest Desk to drive the new speakers. No measuring, just a past catalog rendered anew from the new horns. Mostly Americana from Nashville. Needs more top end but yeah, these drivers should ultimately render that. Completely awesome with a full sound and large soundstage ~ I am very ready to tote the towers to the Front Range and stage with the TU8900R.

Baffle Design... I've had baffle diffraction step "loss" issues with narrow full range designs before (like this one) so I added an extra, larger, optional baffle around the driver. I cut my octagonal baffle from scrap Baltic birch and eased the edges. From prior measurements of the 4" MA Pluvias I saw I wanted to get down to 100Hz reflected into 2pi space. I'd leave the rest of the bass to the corner horn. So, 13560in/sec /8 /100Hz ~ 17". However my biggest scrap piece right now was only 12.8" wide so I'll start with that and make others if I feel it's warranted. The baffle hangs out over the sides and top about 3" (13560/8/12.8 = 132Hz). Measuring will tell the tale of this idea. The supra-baffle is mostly ready... I did change the design to one which hangs around the speaker top, so I won't have to change drivers to the supra-baffle.

Meh... they not only look kindof goofy but my measurements didn't show the improvements in the frequencies I'd hoped (see supra-baffle vs none below) in mid-bass... the back horns already carry the day. Any adjustments needed can be done in EQ, and I will keep the cool FrugalHorn naked look. I am not delusional, there is not much below 70Hz... the kit relocated to COS will get full support from the NanoSub... but I will tune it down from the much higher cutoff required in support of the NanoOnkens.

System Integration @ Blodgett... Mated to the nearly infinitely variable Elekit amp I should be able to come up with something very nice sounding. My next experimental space for the FH3s is the cathedral living room @ Blodgett ~ it's not an ideal side wall setup but will have to work. I first tested the right speaker positioned against the side wall and 6 ft off the wall. There was insufficient difference to warrant the "wide" placement. The bass response of the FH3s in either position is excellent. Music is tighter with the narrower position.

I did subwoofer integration adjustments with the miniDSP. The NanoSub is only a modest improvement augmenting the already solid low end of the FH3s when in sufficient corner spots.
I added PEQ filters on each channel of FH3s (which wasn't quite warranted from measurements but I wanted to see how close to optimal I could get). I removed the NanoSub, at least temporarily, and tried 2 ideas, EQ and EQ', as shown below against the NoSub NoEQ sweep. Again, not a lot of "improvement" versus the FH3s running unadulterated.
I reviewed again the bass responses of the FH3s, the NanoSub, and both together. The NanoSub does not add sufficient freq coverage over the FH3s alone. Yet, distortion is higher when "forcing" the FH3s to produce the low notes via the back horn ~ hmmm, who cares, isn't the point of the FH3 to get "more out of less" - I removed the NanoSub completely.
At the end of the day I also "retired" the miniDSP from the Blodgett Living Room stereo, it wasn't needed as it was with the NanoOnkens and without a need to drive a sub at line level, see ya. I also removed the AirPlay wireless widget... it stuttered and was lower quality than a righteous BT AptX HD wireless stream so I wasn't using it. The current "final" stereo in the Blodgett Living Room (BLR) is much less complex, wholly unadulterated, and a very cool full range sounding kit. I may yet take another pass at EQ/DSP but for now this thing sings, and it's so cool too ~ the DRC FH3s loaded with MA Pluvia 7.2HDs, driven by the Elekit TU8200R with Tung Sol 6550 power and Valvo ECC82 pre-amp, are GR8.

Update 29Mar25 ~ Finishing the DRC FH3s... Springtime temps in the 60s came to Colorado so I prepped for staining & poly finishing the FH3s. True Black oil stain is super messy, but worth it IMO. I decided not to make the sides Sedona Red after the Onken-like center channel staining was difficult to keep lines clean, and the end result just wasn't as compelling as I'd hoped ~ I returned to "my signature" all True Black with satin poly. After stain residue was laboriously wiped off and dried for a day I went to finish with polyurethane. I like two coats of spray (75% poly/25% lacquer thinner @ 25psi) with 400 grit hand sanding after and then a final foam brush on layer. They look cool.

Update 08Feb26 ~ Moving The FH3s To Lower Level... Ultimately usurping our living room for listening to the the EleFrugalKit was problematic. It was accessible and sounded good but sound emanated throughout Blodgett and bugged non-listeners. I moved the entire kit to the lower level and positioned it alongside the Blodgett Theater mains ~ I did not integrate it with the theater however - it is its own separate system and now the JRiver streamer has a display output to the Panasonic monitor. The new location is fine with listening comfortable on the old sofa and the display is a nice (but distracting) feature. I measured the new location from listening position, without any further tweaks ~ good response.

Update 15Feb26 ~ Blowing Up MAP7s & Dialing In The EleFrugalKit 'UI'... Ok, with the EleFrugalKit sounding better than the Paradigm Research theater I thought I'd try to bolster the latter's performance by bi-amping the FHMK3s alongside the Paradigm towers. Briefly sounded great but it was a bad idea ~ I must've over-driven the tiny MAP7s in the FHMK3s and blew out the drivers. I challenged Mark Audio though and they replaced one free of charge; I replaced the other. Ugh. Here are the pics where I tried to cyaniacrolate the cones back together but that was fallacious. Also here is a good cone on the Mark Audio Pluvia 7.2 HD. These are great inexpensive drivers and the fail was mostly my fault ~ it won't happen again with them back on the 4 watt Elekit amp.


Sunday, February 16, 2025

NorCal With Friends & Family Valentines' WE ~ And Car Trouble In The Atmospheric River 12Feb25-16Feb25

It's been several years since our last visit to NorCal to see family and GR8 friends there... I arranged a trip back in Dec24 to head up over Valentine's Day & Prez Day WE (when I'd not wanna be in Summit, whatever the snow conditions). We stayed at Letha's on Wed night so the inbound storm would have a reduced chance of impacting our travel to the airport. It was great to see her and Matt, and spend time in "Kala's room," and dine fine at North County Mex with them. Wed... Getting to the airport came off without a hitch and we landed in SFO in time for the atmospheric river hitting the area. We drove straight to downtown SF to our friends' Bill's & Michael's place. It was a fabulous spot Bill has had for many years. We beat the pending rain by a smidge and hit Golden Gate Pk for a hike and then talked and toasted before going to excellent Chinese in the 'hood. Michael's tiny Fit car, and his driving, was perfect for the task.

We crossed the GG Bridge toward Berkeley and our hotel, the Aiden, near the marina there Wed night and found free street parking 6pm-9am (vs $30/day @ hotel). Nice new place with a comfy king & OK WiFi for us. Thu... We dined nearby at Ken's recommended La Note before heading down for a day with Ed & Laurie. La Note was French style American and good.
Back in the car to head to Mtn View and the skies opened wide. We have a brand new Jeep Compass with nice new tires so hydroplaning wasn't and issue on 880 southbound around the bay. However, we picked up a construction staple and massive metal and quickly lost air pressure to flat. Great ~ I limped to a parking area quickly but one without cover. I donned the raincoat and set out to change the tire. Many calls to Avis and AAA were never heeded by humans so we were on our own. I got it done and we headed to Silicon Valley. I tried four places for tire repair kbefore meeting Ed but all were too busy to completely inattentive. Hmmm...
We met E&L at their place for a chat and then a coffee out. We debated the world's and humans' issues but solved precious few... there were ideas but yeah ~ it's hard. We all headed to downtown Mtn View a block away for our keen dining & totties experience at Scratch. That was a blast with tasty scallops and branzino and fafarelle as well as excellent custom drinks. We rested a smidge after but soon enough headed back in the rain to free street parking in Berkeley near the Aiden.
Fri... Happy Valentines Day! We dropped the stapled tire at Don's who will repair it. We then headed to Berkeley Art Museum & Pacific Film Assoc (BAMPFA) to view some keen art installations as we awaited cuz Ken's availability. Nice, though some abstract stuff is beyond us; maybe it was just the colors but we liked this big piece...
We met Ken at Steph's ADU that he's renting while he lets his primary house. We dined at delicious Dumpling Time for lunch, after a review from Phia, Steph & Craig. It was excellent.
We returned to Steph & Craig's home and talked family stuff a bit then Ken took us on a nice tour around upper Berkeley: past Ruth's and his homes, up to Lawrence Science, over to Berkeley CC, and down and around Strawberry Canyon back home. The outing was cool but while out I got the call from Don's about the non-fixable (brand new) tire... grrr. We did tour an ADU supplier in all teak from <>, $350K for 500sqft! Their secondary biz is furniture supply ~ cool stuff in teak we've noticed before, Masaya, a Nicaraguan company making finished goods ~ I really appreciate when a less "developed" country pursues more added value in their exports, rather than just exporting raw materials for someone else to advance. Good on ya.
That evening we went out together to Tuts! for dinner and Fieldworks for some beers and tiny Trivial Pursuit with Erin, a friend of Ken's from pickleball (no pic at FW). We hadn't seen the travel TP before but the cards were impossible to read without iPhone zooming or the tiny magnifying glass they provided.
Sat... We were off to American Canyon to visit Mike & Betsy. But first we loaded up with brunch items from the Cheeseboard and Andronico's to share with M&B and hopefully Lisa and her boys. It was a great brunch and all day chat with Mike & Betsy and a dinner and early evening visit with Lisa, Mazi & Obi. Lot's of the floor is lava and charades and more. Lisa and the boys seem great and Obi's 1st soccer game is tomorrow! Mazi's favorite sport is baseball, and he's good, and his fav subject is math... fine combo. I was even able to assist Mike by re-attaching a motion sensor to his IoT network.

Sun... Well at 11pm Sat night we were interrupted by the hotel fire alarm and dang loud sirens. We changed from undies to street clothes and headed down and out. Someone just burned the PopTarts in the kitchen but we got 2 trucks/alarms.

We did breakfast with Ken on 4th St before heading to SFO to turn in the car with the whacko tire. I've already received the "damage report" from Avis, 'cause I reported it ~ we'll see how much they charge me.

We caught MLC @ Torchy's on the way home. It's been another fun trip to NorCal visiting family & friends ~ thanks for sharing with us everyone.



Sunday, February 9, 2025

February Music Appreciation ~ Just Stuff I Like 09Feb25

I've been skiing and building audio systems... now some listening & sharing. I have no common thread but I've been inspired a skosh by some visits with MN youngsters Jacob & Conor. Here's mainly stuff I couldn't show due to time constraints. Kendrick Lamar's half time was pretty cool too though.

Building The BFM Center Channel ~ The Onken-Like NanoCC Rockin' With The NanoOnkens 09Feb25

Blodgett Family Room Center Channel (BFM CC)... Yeah, I haven't built a speaker in a couple weeks so I literally dreamt of a shift to bolster the BFM's new sound ~ try the NanoOnkens in there! It'd be a solid upgrade but I need two things then: 1) a center channel speaker to match and 2) replacement speakers for the Elekit living room tube amp system. This post deals with #1; you'll need to wait for the replacement speakers alluded to by #2. I will say however that in each case, I am a fan of the ~$50 Mark Audio Pluvia 7.2HD full range drivers and bought 3 more of them. Most center channel designs are smallish, especially in height, as they are best placed directly above or below the TV/monitor in a theater build-out. I really like a tight Onken full range sound and the DIY FrugalHorn team (DLugos diagram) drew up a decent, and small, center channel for a variety of MA drivers to mate with those horn designs. Slick, Fb tuned, restricted bass ports, abreast of the Mark Audio drivers. I used that core design to create an Onken-Like NanoCC with a 4" MA Pluvia driver and using leftover 15mm Baltic birch. The new speaker dovetails well in sound and look with the NanoOnkens. I prefer a soundfield built from all the same drivers; it keeps the timbre consistent. I'm replacing some low-end Paradigm bass reflex speakers for the front 3 channels of the BFM system (I've repaired them a couple times already, and replaced the sub). The new NanoCC, and the sub, are behind the acoustically transparent fabric panel below the TV.

NanoCC Design & Cut Sheet... I first took inventory of all the 12mm, 15mm, and 18mm Baltic birch plywood I have. This so I could map out the parts needed against the cabinet raw materials. It's not a classic cut sheet but the process worked so I could use all 15mm for the NanoCC.

I got the parts cut on my table saw and drill press from the leftover 15mm scraps. That includes a front baffle with a 102mm hole for the driver cut with a hole saw and the rear side eased 45° via a router, as well as a brace with holes. Stack of stuff looks "nano" as hoped and took just an hour.
Assembly was pretty quick with just clamps and Titebond 3. From dry fit to final box was 90min. I laid down and aligned the vents as a 2nd step. Acoustical physics analysis on these 9mm ports is not for the faint of heart ~ Onken conviction.
You see the case is heavy and the driver will be braced ~ inert cabinetry is your dearest friend. Never go flimsy on anything... I even glue flute all the seams on the inside to assure security and air seals. I actually learned this best as a kid building custom rockets and needing to assure fins didn't rip off at torque/lift-off. I also dipped into the scrap piles of damping materials when completing the NanoCC. I used 1" wool for key surfaces but stepped to 3/4" for corners and even 1/2"poly between the chambers. All DRC full range builds are heavily damped and super rigid. The cabinet is done but for binding terminals and a driver ~ and perhaps some finish... that "active" stuff is back in COS, where the NanoCC home will be.
Equalizing & Measuring... My first task after installing the new NanoCC and L/R NanoOnken Mains, all based on the MA Pluvia 7.2HDs, was to use the new Onkyo's AccuEQ system to dial in the 3.1.2 array (we have in-ceiling pressence/height speakers in the rear). With an included measurement mic I invoked the automatic measuring system in the Onkyo and let it do its thing for 5min. Always just white noise... no sweeps. Sounds fine ~ far more defined and dynamic than the old speakers, so the upgrade is working well so far. I next measured the NanoCC and the entire NanoOnken-NanoCC-SVS Sub system in place in the Blodgett Fam Rm. The orange below though is just the NanoCC in free space, where it does exhibit baffle diffraction step "loss." However, with the AccuEQ running and the sub engaged, the sweep is down-bending as desired, and sounds quite good. I don't fully understand the wiggles 5KHz-10KHz or the 5-10dB loss 10KHz-20KHz but the room is pretty padded and the measurement are taken kind of off axis (below the mains and above for the center channel) from the speakers' drivers... the speakers are not in ideal locations for listening, but they are out of the way.
The Nano upgrade to the BFM system and driven by the new Onkyo AVR is sharply improved for music and movies.

Update 12Mar25 ~ Finishing the NanoCC... I got after finishing the NanoCC despite it being buried behind a curtain. I chose a Sedona Red for the upper and lower part of the cabinet and my normal real black for the middle near the driver. It's all in an attempt to match the copper cone, and test how future FrugalHorns might look using the same scheme. Hmmm; it looks OK but the lines for transitioning from red to black are hard to keep clean. I kick that decision down the road.

Friday, February 7, 2025

Wrestling The Thermal Expansion Tank ~ There's Always Something 05Feb25

Today was an adventure. I knew my thermal expansion tank on the hot water line had failed and was full of water. And I received lots of alerts on my flood sensor since it was backed up and leaking onto the floor through a relief valve. I knew basically how to proceed with replacing it and had already bought the replacement tank and a pressure gauge. However, while attempting to remove the tank from H2O system, the pipe it was screwed onto just sheared off. I had to turn off every thing, drain hot water from house, and repair piping with new copper & fittings. I had to buy all that stuff and tools like a pipe cutter, pipe cleaner, flux, solder, propane. Sheesh. By 4:30pm I was back where I expected to be at 10:30am... measuring pressure. The basic process requires measuring water pressure in the system, and pressurizing the new tank to that level, before installing it. Pics in reverse chron...


Wednesday, February 5, 2025

Ski & Party With Bro Brown And Yoho During Guys Week ~ MN Mafia In The 'Hood 05Feb25

It is that time of year when lifelong friends, and family (yeah, all male) of Bro Brown come to Summit for winter fun. I usually visit, dine, and ski with these Minnesota Mafiaosos some during the week long event. Too, my buddy Yoho joins as well for parts of it. Well, with a less generous pass held this year, Jim & I only jointed for Breck & Keystone outings. And, through strange administrative turns, Jim didn't get his normal Epic Local pass this year and I had to flip him some Buddy Passes... dang, even they are very expensive. Too, at the ticket booths not everything was smooth ~ there's some glitch in the system with Jim's pass. Anyway, try as we did to catch up with Richard & Brown and their team, we couldn't at Breck and didn't at Keystone. The last we saw of Brown-sign was parking next to the Vanagon in the Airport lot. We did share some pops at Broken Compass after runs at Breckenridge, and we did dine that evening at The Lodge. Later in the week we skied another nice day (weather here is 20° above normal right now so think spring snow conditions) at Keystone. Part of the show is giving the young Brown & Hubbs boys some music education via the NestMT... it was a good time with them too, despite missing them on the slopes. Yeah that's a decent shot of the 10 Mile range from atop Bergman at KS.



Saturday, February 1, 2025

Broken Compass & Yonder Mountain Concert @ Lulu's Downtown 31Jan25

Scott & I heard Broken Compass Bluegrass at Lulu's with friends David & Lisa. The band was excellent with a fine 45 minute set as openers for Yonder Mtn. We arrived a smidge late by my standards, from a good dinner at Jax across the street. That kept us from position A on either of the rails overlooking the stage & mosh pit. It didn't temper the vibe though and folks were fairly decent about not standing right in front of us.  We all really enjoyed BCB, but Scott less so. He and I departed during the break between the bands so we did not get to hear Yonder Mountain String Band this time. Too, it was a medical situation that kept the Fretliners from playing in their scheduled spot as the number 2 act for the night. The sound seemed better at Lulu's this time out but still could be improved with more vocals in the mix. As described prior BCB is an excellent Nor Cal group quickly emerging in modern alt bluegrass; I was really pleased to see them in our small club in Colo Spgs. I doubt that standing will last long. Their musicianship and skills are very strong; their writing it good; their vocals were good ~ even bringing 3 part and 4 part harmonies on occasion. They played some great covers, some classic bluegrass, as well as good originals. They didn't really come to the merch table after their set so I did not get signatures, and they played from memory and didn't have a setlist. It was a blast.