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In the Forum: Horn-Loaded Speakers
In the Thread: The absolutely “best” material for horns construction.

Post Subject: Ain't no shortcutPosted by jessie.dazzle on: 6/26/2009

Absolutely true; I end up breaking and rebuilding the mold (actually an internal plug) for each half of the 40Hz horns I'm currently making. Ironically, the resulting horn ends up looking like a mold.

For the 115Hz horn, I managed to coax two complete horns (again 4 halves) from the original, and quite robust mold; after which it was trash.

The smaller horns were made by rotating a steel template about a fixed axis. The 180Hz horns were about as large as I'd want to try using this technique. Its still very time consuming.

With what I now know, having the same limited means, I could improve on the process, but only in as much as to make tooling more durable. The right way to do it is to get someone to pay for proper industrial tooling.

I'd probably quit my day job if :

1) I could find a venture capitalist/horn freak to fund tooling for injection molding , allowing manufacture of horns from resin (possibly loading the mix with fibers or a particulate solid).

2) The much rumored new/old Vitavox drivers turn out to be good and available.

jd*

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