Zaph Audio ZA5.2 TM build progress

[Rick Sykora]

I had to clear off my table saw and order some parts (found I did not have good port tube and enough damping sheets that are required). Thought I would share the build progress. Here is the basic cabinet for starters:

The cabinet plans leave room for interpretation, so loaded into Bassbox and this was the result. I made one adjustment to allow for a removable front baffle (also according to designer’s spec). The glue is still setting so have some time as I expect parts delivery later today. If all goes well, planning to ship completed unit to Amir by end of week .

 

[Rick Sykora]

Front baffle is cut...


Forgot about the woofer chamfer so will have to get creative there. Parts showed up before the latest snow storm thankfully . After snow shoveling, worked on crossover layout. Normal kit supplied board is rather long. If I decide to glue front baffle, will not use as cannot be removed. Once chamfer is done, will do baffle round over.

 

[aarons915]

Interested in seeing how these measure, I heard them a few years back and they sounded really good for the price.

 

[Rick Sykora]

The woofer chamfer slowed me down more than I thought. For previous builds, I just did a roundover as I did not have chamfer bit. If would have remembered to do the chamfer before I cut the hole, could have gotten by with my v-bit . After trying a few jig possibilities, broke down yesterday and bought the chamfer bit.

Wonder how significant the impact of the chamfer is, but I agreed to build to the design!

In case you are wondering what a woofer chamfer is...

 

[Rick Sykora]

Final fitment looks good but will need to countersink the port...



Btw, to save time and dust, the baffle holes were cut with hole saws and used rabbeting bit to countersink. Port countersink is only 1/8, so will do manually. Quick check reveals the crossover board should fit. However only fits on back and design calls for 2 layers of damping sheets there...

 

[amirm]

Great to see this build thread to go with future measurements. Thanks for creating it.

 

[Rick Sykora]

Crossovers built and ready for initial test...

 

[Biblob]

Crossovers built and ready for initial test...

View attachment 50593

No bracing in this enclosure?

 

[Rick Sykora]

No bracing in this enclosure?

The designer left any bracing as optional in this small cabinet. A knuckle rap test indicates it might need. I cut one and it did help. It is not installed as it would have been in the way during crossover install and testing. The initial FR test looked pretty good, so will install brace and glue baffle tonight.

 

[Jinjuku]

Johns woofers are a good bang for the $.

 

[Rick Sykora]

Hit a slight snag and had to go buy a new sander. Here is pic after sanding, stuffing and bracing...

Now that most of the innards are in place, time to glue on the front baffle, rewire and wrap up!

 

[Rick Sykora]

Was not planning to paint, but this one comes back to me after Amir tests. Had not used Duratex before but had a quart in stock. Even with smooth roller, the finish is textured. It dries in an hour or so, but can take days to cure. Amir has plenty to test, so we agreed to hold off shipping. Will reassemble over weekend and do final test...

 

[Rick Sykora]

Done with final measurements...

Measurements are 1m, on-axis, REW 75 dB level, no smoothing and gated...

 

[Rick Sykora]

UPS ground now has it on the way to Amir!

 

[Kustomize]

Hello @Winkleswizard

Would you be able to help me? I have the Zaph 5.3T built. I was just wondering why your tweeter top response looks like that, while mine measures like this?

This is done at 1 meter away, on axis, UMIK-1 pointed right between the tweeter and top woofer, psychoacoustic smoothing applied.

This is both the Left and the Right.

 

[Jon AA]

One thing to check is that you're not using the 90 degree calibration file if you're pointing the mic at the speaker. I assume you're gating the measurements? Regardless, nice looking measurements.

 

[Kustomize]

One thing to check is that you're not using the 90 degree calibration file if you're pointing the mic at the speaker. I assume you're gating the measurements? Regardless, nice looking measurements.

No gating.
I didn't see the 90 degree file.

I noticed the early reflections dotted line included at the bottom of the measurement, are closer to my measurements. Could it be reflection? I do have a relatively reflective room.

Thankyou!!

 

[Jon AA]

I always use gating on close measurements where you're trying to get quasi-anechoic data (really only good for higher frequencies unless you're measuring outside). Something like 4 or 5 ms, depending upon how far off you are from reflections (including the floor). You can look at the impulse response to give you some guidance.

However, I don't think that's the issue you're seeing at the top end. I'd suggest measuring on-axis with the tweeter to see what difference that makes. Though generally you'd expect to see the opposite of your measurement (top end rolled off more) if you're off axis. Interesting.

 

[Kustomize]

I tried gating and used on axis right on the tweeter. Doesn't help. I tried gating 4ms and tried 5ms too. Graph becomes weird, but doesn't change the top end of my tweeter at all.

The early reflection dotted line shown in the measurements, what is that? It kind of matches my top end...

 

[Kustomize]

Hit a slight snag and had to go buy a new sander. Here is pic after sanding, stuffing and bracing...

View attachment 50885
Now that most of the innards are in place, time to glue on the front baffle, rewire and wrap up!

Could you tell me what foam you used?

Also on the side with your crossover, did you put foam there and install crossovers on top? Or did you leave the side with crossovers untouched?