Ok, Here is
where it gets a little tricky...
The fronts of these speakers are to be covered in black acoustic cloth.
Dan had also requested a rear acoustic cloth cover that ideally could be easily removed. He also stressed that it should look continuous and reflective of the overall smooth flowing aesthetic found in the rest of his design.
We came up with an idea to do a simple wrap that goes around internal forms and terminates close to the front edges of the baffle.
In order to have something there to attach to I needed to make small side sections ( Rails) that Diana could later cover with Velcro . The idea being to start on one edge and sort of stretch the fabric around forms and finally attach on the opposite side.
The rub with doing this is
the curved shape and the very small amount of internal space remaining after we make mounting plates, to actually fit these side rails onto.
These rails needed to be strong, stiff and sufficiently wide enough to attach fabric to but they could not be very thick .
I came up with the idea of using 1/4" thick Baltic Birch that can natural bend to follow the baffles outer curves without making the usual saw kerfs like I would if using a thicker piece.
1/4" X 1" tall is
plenty for attaching velcro and fabric to and is
actually as it turn out very stiff as I have done it.
The procedure that makes all this
a curved dado recess for the wood rails to seat into.
I plowed a dado approximately 1/4" deep and 1/4" wide, exactly following the outside contours of the baffles edge.....
I then flooded this
area with glue and forced the 1/4" side rails into place.
Once fully in place I ran staples from the outside through this
Here are a few shots of these side rails and insertion depth as seen from the end.
To be continued.....