Australian Technical Production Services

AST0801 Foldback wedge

Having assembled the two Side plates we are now ready to assemble the rest of the wedge
The rear baffles (for want of a better name) A B C & D fit around the Sub plates as shown below again you may want to put off gluing the pieces together until you have made sure they all fit nicely.

note that you will need to cut a couple of pieces of wood from the angled lengths O and P for mounting the front Baffle.

When gluing make sure the joins between the rear baffles are Glued well by running a bead of glue between them as all the joins need to be air tight:

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Timing for the paint may vary according to the Resin you use but is usually half the cure time for the resin (check the instructions for your Epoxy Resin).
I used Dulux enamel to provide the top coats and this has (so far) turned out to be reasonably durable Rockard is also worth using.
Build up the paint good and thick to get a smooth finish - if you have access to a spray gun that would be good. Note be careful not to get any paint in the thread of the T nuts for the stand mount.

Line the inside of the wedge with foam and mount the crossover - Note that this is a tight fit and the Relay needs to be towards the front (as per the pictures below) for it to clear the speaker.

Solder wires to one of the Speakon connectors making sure that the wires to the other connector are long enough to reach through the mounting hole on the other side of the wedge. Mount the connector using self tapping countersunk screws, pull the wires through the opposite hole and solder them to the other connector. Mount and screw in the other connector and connect to the crossover.

Line up the front baffle and the front spacer and screw them together - check that these fit the front of the wedge and plane the edges back if they are too big.

Mount the front Baffle and Front spacer and trim mesh to fit the front of the wedge. I managed to find a countersunk screw that neatly fitted the holes in the mesh.
Note that I have since found that the grill will loosen over time causing rattles, so it is a good idea to use a piece of felt or foam rubber (not shown in the pictures above) behind the grill to dampen this out.

Connect up and mount the speaker - Remember that the tweeter is connected out of phase according to the markings on the crossover (i.e. + (red) on the tweeter to - on the croosover and - (black) on the tweeter to + on the crossover).

Stick Velcro strips around each edge of the mesh and use this to hold the Speaker foam (also sold as Air conditioning Filter).

Your wedge is now complete and ready for use.