Zeppelin 1x8 Cabinet Manuel utilisateur

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THE PERCOLATOR

2 WATT TUBE AMPLIFIER ASSEMBLY INSTRUCTIONS

SPEAKER CABINET

ZEPPELINDESIGNLABS.COM • 2950 N. WESTERN, CHICAGO, IL 60618

Assembly Instructions

2WATT TUBE AMPLIFIER

SPEAKER CABINET KIT

1x8 SPEAKER CABINET

ASSEMBLY INSTRUCTIONS

INTRODUCTION ...................................................................................................... 3

CAUTIONS, WARNINGS & DANGERS....................................................................... 3

WHAT YOU WILL NEED ............................................................................................ 3

WHAT’S IN THE BOX................................................................................................ 3

BUILDING THE CABINET ........................................................................................... 8

A WORD ON COUNTERSINKS .............................................................................. 9

ASSEMBLING THE BOX.......................................................................................... 9

FINISHING THE BOX ........................................................................................... 24

BUILDING THE BAFFLE BOARD................................................................................. 29

MAKING THE SPEAKER CABLE ................................................................................ 42

PUTTING IT ALL TOGETHER ..................................................................................... 47

USING YOUR NEW SPEAKER CAB .......................................................................... 50

BREAKING IN ..................................................................................................... 50

DRIVING CAPACITY............................................................................................. 50

REPLACING THE SPEAKER .................................................................................... 51

INTRODUCTION

Thanks for buying a 1x8 Speaker Cabinet kit from Zeppelin Design Labs! We hope you will have fun

assembling this kit, followed by many years of musical enjoyment. We think we’ve produced a pretty

nice product, and we’d love to hear your feedback. Send an email, or post on the ZDL forum.

Note your kit includes a serial number sticker for you to attach to the speaker frame. Reference this

serial number whenever you contact us for assistance.

Please read this manual ALL THE WAY THROUGH BEFORE STARTING! You will discover a number of

issues concerning timing or sequencing that you might not realize if you just start out.

CAUTIONS, WARNINGS & DANGERS

This is a simple, beginner’s soldering and carpentry project. If you have never handled a

soldering iron or a router before, this project will give you a little beginner’s practice.

This instruction guide is full of CAUTIONS,WARNINGS, and DANGERS. These are actually three

distinct things:

1. CAUTION indicates a potentially hazardous situation that, if not avoided, could result in minor

or moderate injury, like cutting or burning your ﬁnger.

2. WARNING indicates a potentially hazardous situation that, if not avoided, could result in

death or serious injury, like shocking yourself at a wall receptacle.

3. DANGER indicates an imminently hazardous situation that, if not avoided, will result in death

or serious injury. This word is limited to use in the most extreme situations, like electrocuting

yourself or cutting a ﬁnger off.

Follow the instructions and stay safe!

WHAT YOU WILL NEED

To build and ﬁnish your Speaker Cabinet, you will need the following:

1. Tools

• Drill: cordless, corded, or drill press

• Drill bits: 1/16, 9/64, 7/32

• Orbital Sander (optional) or sanding block

• Small router and 3/16” radius roundover bit, or other small detail bit (optional)

• Countersink (see “A Word On Countersinks”, on page 9)

• #2 Phillips Screw Driver or screw gun

• Small straight screw driver

• Awl, or nail and small hammer.

• Staple gun: manual, electric, or pneumatic

• Sharp pencil

• 12” Ruler

• Bar clamps, minimum 12” opening, two of them

• Utility knife or X-Acto knife or scissors

• Heat gun, or very hot hair dryer

• Soldering Iron, good quality, 15-50 watt

• Wet sponge or dry solder-cleaning pad

• Wire stripper / cutter, to strip 16-gauge wire

• Needle-nose pliers

• Some sort of clamp or ﬁxture to hold parts while soldering. Your bar clamp might work.

2. Supplies

• Solder, rosin core for electronics

• Good quality wood glue such as TiteBond II or III

• Masking tape

• Good quality wood ﬁller such as DAP Plastic Wood (optional)

• Sandpaper, either discs for your orbital, or sheets for your block: 60, 120, 220, 320

• Very small can of MinWax Dark Walnut Wood Finish (oil-based stain) or equal

• Small can of MinWax Wipe-On Poly, clear satin, or equal

• A small amount of ﬂat black paint, spray or can

• Mineral spirits, for cleanup

• Clean rags

WHAT’S IN THE BOX

Table 1 on Page 6 shows a complete parts list of everything that

should be present in your kit, followed by nice color pictures

of each part. Print the parts list and carefully go through the

kit, identifying every part. Besides verifying that nothing is

missing, this will acquaint you with the parts and their names.

If ANYTHING is missing, or damaged beyond use, ﬁrst double-

check: we double-checked before sealing the box at our lab! If it’s

still missing, EMAIL US right away at support@zeppelindesignlabs.

com. Include your serial number (on a little round sticker in the bag of hardware). If we are reasonably

convinced that we goofed and shorted your kit, we will get replacement parts in the mail ASAP. If you

lose or damage anything, we will be glad to sell you replacements. The unusual or custom components

can be ordered from us direct. For more common parts, like screws, you should just go to a local

hardware store.

There are three components to your 1x8: the cabinet, the bafﬂe board, and the hookup cable. You can

complete these in any order, but we think the process will be most efﬁcient if you work on them in the

order in which we present them here. In any case, READ THE WHOLE THING THROUGH BEFORE

TIP: Empty

the parts of the kit onto a

cookie sheet or into a big fruit

bowl, NOT onto the cluttered

workbench, or onto the living room

carpet! This will protect you from

losing tiny parts.

STARTING! The bafﬂe takes less than an hour to assemble, plus paint drying time. The cable takes

about 15 minutes. The cabinet takes about 3 hours spread over 2-3 days.

Figure 1: What’s In The Box?

Table 1: 1x8 Speaker Cabinet Bill Of Materials

Loose in the box:

Part # Description Notes Qty

BB08 Bafﬂe Board for 8” Speaker 1

CA04.1 Cabinet Top/Bottom Shorter parts 2

CA04.2 Cabinet Sides Longer parts 2

CA04.3 Cabinet Cleat 4

CA04.4 Cabinet Port, solid 1

CA04.5 Cabinet Port w/Hole 1

GC02 Grill Cloth Black/Silver/Beige 1

LS08 Loudspeaker 8” 1

TM02 Paper templates 2

In Hardware Bag:

Part # Description Notes Qty

CB11 Zip Wire 16/2 6” 2

FT03 Foot ½” x ¼” 4

J2 1/4” Mono Phono Jack, Female Input 1

JA07 1/4” Mono Phono Jack, Male Cable 2

NU03 Tee Nut #8-32 Bafﬂe 4

PL20 Jack Plate 1

PL30 Serial Number Plate 1

SC13 Machine Screw Pan Head Philips #8-32x3/4 Speaker 4

SC61 Wood Screw Flat Head Philips #6x1-1/4 Cabinet 24

SC65 Sheet Metal Screw Pan Head Slotted #4x5/8 Jack Plate 4

SC66 Sheet Metal Screw Pan Head Philips #6x5/8 Feet 4

WA06 Flat Washer #8 Speaker 4

WA10 Countersunk Washer #8 Bafﬂe 4

Figure 2: Parts Illustrations

CA04.5 GC02 LS08 CB11 FT03

BB08 CA04.1 CA04.2 CA04.3 CA04.4

J2 JA07 NU03 PL20 PL30

SC13 SC61 SC65 SC66 WA06

WA10

BUILDING THE CABINET

The cabinet is a beginner’s woodworking project, but it will take several hours over several days to

complete! Take your time, be careful, and you should produce a lovely, great sounding solid wood

cabinet to be proud of.

We are going to show you how we make the preﬁnished 1x8 here in our lab. There are as many

carpentry and ﬁnishing techniques as there are carpenters and ﬁnishers. If you prefer to do something

differently, go for it. If you have an experienced friend to work on this with you, take his or her advice

over ours.

Following is a parts diagram of the cabinet. The part numbers are keyed to Table 1: 1x8 Speaker

Cabinet Bill Of Materials, page 6.

Figure 3: Exploded Parts Diagram

A WORD ON COUNTERSINKS

The overall success of this project depends somewhat on your ability to accurately countersink the

wood screws, so that the heads lie just below the surface of the wood, but no deeper. There are several

ways to do this:

• Buy a #6 pilot bit (9/64) with matching ﬂuted countersink and stop collar, or an all-in-one #6

pilot / counterbore / countersink tool.

• Buy a countersink bit.

• Use a ¼” drill bit in a drill press.

The ﬁrst (shown to the left) is my favorite: very accurate and easy to use. The

second, a countersink bit (shown to the right), is next best. If you don’t do a

lot of wood working, you may not want to invest in these tools. This leaves

using a ¼drill bit in a press. To do this, ﬁrst drill through with the 9/64 bit,

then countersink with the ¼bit, carefully and gradually adjusting the depth

of plunge until the full diameter of the bit just barely cuts into the wood. The screw should then pull the

head down into the wood and just below the surrounding surface. Practice setting the depth on a scrap

of pine until you like the results.

ALWAYS provide a 1/16” pilot in the holding piece of wood, and keep the clutch on your screw gun

set low when driving, or the screws provided are likely to spin out or break.

ASSEMBLING THE BOX

1. Fitting the Wood Parts (Part # CA04.1&2): Note that the shorter wood pieces (Part # CA04.1)

are the top and bottom and the longer pieces (Part # CA04.2) are the sides. Arrange the four

pieces of wood as shown. If you have a preference for the appearance of grain, color, knots, etc,

ﬂip the parts around this way and that until you like the way they look. 4

2. With the pencil, label the parts where it won’t show so you can easily ﬁt them together again later.

Put the labels all towards the front.5

3. Marking the Jack Plate6: Install the 1/4” input jack (Part # J2) into the jack plate (Part # PL20).7

Fit the jack through the hole in the Port (Part # CA04.5).8Use the pencil to mark the four screw

holes on the Port.9Put a pencil mark on the Port and a matching dot of masking tape on the Jack

Plate so you can install the plate later in the same orientation.10

8 9

6 7

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