BR-26 New Baffle

The somewhat unusual construction of the cabinet allows for a new rectangular baffle to be cut and installed without major modifications to the rest of the enclosure. In order to achieve this, I have fabricated a new 1/4" ply backing plate which is glued into the cabinet, forming a back stop for the new 5/8" mdf baffle.

Clamping backing plate in place

Backing plate with rough cutout to ensure driver clearance

Both drivers are flush mounted in new locations, with the woofer centered horizontally, and the tweeter offset slightly in order to make better use of the available space.

New baffle with cutouts being clamped in place

Aesthetics are not a priority at this time

Res-stuffing with the original material

 Unfortunately the Visaton woofer does not come with a gasket so I had to make my own from a sheet of fibre reinforced rubber that was in the shop.

New woofer gasket

 I hacked apart two PE buyout terminal cups in order to make a 4 conductor plate and allow for bi-wiring the drivers and external crossover adjustment.

Parts from $2 Energy branded terminals

Everything in place with temporary screws

Grill

Visaton W130S

Here are some photos of the new 5" woofer. Considering the $25 price tag, I am happy enough with the build quality, but not in any way impressed. The basket is stamped steel, which is fine, but I would have preferred a sharper edge on the exterior of the flange. I believe it might look there is a bit of a gap (as though the mounting hole is too large) when flush mounted, even when the back side of the flange is perfectly fit...

Measurements to come at a later date.