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Directiva r1.2 design and build

Thanks to @terryforsythe , @Paweł L, and @RickS for the guidance on this.

One bit of background data: The prototype was chamfered at 22.5 deg around 2/3 of its full 33 mm thickness, as shown below. It showed no evidence of any issues in the 1.0-1.2 KHz area. The full thickness of the baffle is 38 mm. The inside edge of the chamfer comes very close to the enclosure wall.

Screenshot 2025-05-13 at 2.27.36 PM.png


For the new baffle, I've already cut the 19 mm deep rabbet on the inside. I think I have two options:

1. Chamfer at 22.5 degrees as before, except where the mounting screws come through. More material has been removed than in the prototype, due to the straight portion where the rabbet has been cut, but of course the shape is different and there are the lands where the screws go.. The side wall is now shown for reference. This looks similar to the example that @RickS provided.
Screenshot 2025-05-13 at 2.46.14 PM.png


2. Chamfer at 45 degrees, except where the mounting screws come through.

Screenshot 2025-05-13 at 2.52.41 PM.png


Suggestions?
 
I did 45, but mainly because that’s the router bit I had available. It was available because the kit specified 45 and I bought it to follow directions, not because of any actual data.
 
Since it's been three weeks, one pic from the process of fitting the baffles to the enclosures. I was not happy with the enclosure finish so I've taken a lot of time to get it right. We want a relatively flat finish. Flat water-based polyurethanes are notorious, I've learned, for showing brush strokes. I don't have a sprayer, so I've reverted to something I've done before: Apply glossy finish then buff down with abrasive pads to 0000 steel wool. I'm close to being finished with repairing remaining flaws.
IMG_6259.png

Meanwhile, the baffle mounting blocks with elongated holes, along with a thin spacer that sits between the enclosure and baffle are in place. The spacer, glued to the enclosure with silicone adhesive, fulfills two purposes: It provides a visual break between the enclosure and baffle, and also a properly dimensioned O-ring groove for the seal.
IMG_6258.png

And yes - I do need to place holes for the terminals!
 
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