Creating a speaker horn from fiberglass?

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#1

Hello all. I’m a fiberglass virgin and I need some advice.

I owned a set of Image Dynamics horn loaded compression drivers a few years ago and loved them for their clarity and tonal qualities. Long story short, they were stolen and I could not afford to replace them.

Here’s a photo of the Image Dynamics design:

So, now I’m on a quest to make something that will allow me to use that speaker design theory with my own acoustical design. I need to make a fiberglass plug that would allow me to make multiple units. It’s essentially a hollow triangle that has a horn driver mounted in the rear of the frame. I’ve heard foam would be the easiest, gelcoated wood would be the most resilient and even waxed fiberglass…but I’m so cherry that I don’t have a clue.

I’m deeply in your debt and need as much help as possible.

#2

carve it out of foam…floral foam or styrofoam but if you use the styrofoam (insulation of any type)youll need to cover it.

Some tape (masking tape) works fine.

#3

That never even crossed my mind, but it makes perfect sense.:slight_smile:

Do you think that the mold will hold up over a few months, or should I create a gelcoated male plug for longevity? I don’t anticipate any need to make more than about 6 pairs, but I don’t want to need more and not have them around.:eek:

Thanks so much…
Michael

#4

PS foam use Epoxy resins…

PUR foam use PER or Epoxy…

I might be able to help you on the PUR foam if you can’t find it locally.

#5

why gelcoat a plug?

just make the plug…and then wax it, make the mold thick enough to make a couple sets and call it a day.

Id use the floral foam…not sure of the brand but it will hold up to resins of per or ver and then just coat it, sand it smooth and prime it.

Then polish it and wax it and make a mold. Youll probably ruin the plug removing it but who cares? youll have the molds and be set