DIY Radial Horn

smiley20 good to see you back again. just dont go riding any bikes.....

Glued together and ends cut for the comp mount (Hint- it's a 1.4")
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If I ever glued these again, I'd have made a jig to clamp on to beforehand. They aren't 90 degree, more like 88-89, but that isn't much of an error (as is the fact that they are 3mm longer on one end than the other, heh.)

Also - an open invitation to you all - I'm not sure what to do with these (I don't have any 1.4" comps) so would any of you fine gentlemen like to borrow these for a bit, maybe pass them around, once they're fully finished? I only expect nicely done plots in return :lol: .

Looks more like a horn now.

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The gaps in the joins between the wedges aren't really gaps - they are glue.
Needs a lot of sanding before I make the comp mounts.

If anyone wants to try the method - make yourself some jigs, and make sure they're square when they need to be. You don't want to spend hours with power sanders.

amazing project!

amazing project!

After a lot of sawing, regluing, and filling, I have before me two radial horns that should expand right and have squares as throats.

I have two choices - I could machine a wooden adapter by hand and join it to a metal plate on which the CDs would be fixed, or I could get the CNC to do it.

Any other ideas are welcome - I'm taking a break for a bit.

First of all, taking a break is not allowed. If you want a round throat in the horn without distorting the shape with an extension, this is how I do it.
Firstly, having coated the inside of the throat with release agent, block off about 3" of throat with plasticine. Pour resin or similar moulding material into the cavity. When set, remove the plug. You will now have a solid male shape of your throat. Mark the desired throat diameter on the top and then dress the material away over around a 3" distance until you have a shape that will give you a round converting into a square over the 3". Having removed the release agent from the inside of the horn, place the newly formed plug back into the throat, backing it up with plasticine once more. The plug should now have the release agent on it. With the plug in place, pour your resin into the newly formed cavity until it reaches the top. Once it has set, knock out the plug. what you will be left with is a conventional throat for your wonderful horn. Simple.

I swear I posted a reply here.

Thanks for the advice Tony, I'll try to do that if I have enough time in the shop left.

Unfortunately, I check this forum very sporadically now, so I'd already built the adaptors by the time anyone reads this.

Will decide to go wither route again, then post pics.

I've got to leave in a few days, so I've finished machining the adapters. Have sent all by post to someone in the UK, details later. Gave the lot a few coats of spraypaint to tidy it up (It's not smooth at all on the outside - a few craters where I've dropped it, but it should sound nice).

The brilliant thing about this entire exercise is that it cost next to nothing in materials. All ply was scrap, all metal was offcuts, all I spent money on was glue and two cans of paint.

Finished horns shown here: racing stripes cover where I sawed one in half because it fell over overnight and the cheap clamps broke and I thought 'fuck it'.