ESL DIY Kit project

[jasonlky]

Hi all,

After having read through many threads on DIY ESL, I feel confident enough to start my own project.  However, I do not posess the aptitude to build an ESL from scratch like our brothers in the DIYers Project ESL thread.

I have learnt of an ESL Kit provided by ER Audio from Perth, Australia.  The ESL kit comes complete with all components that would be needed to build a complete pair of ESL, with the exception of the wooden frames.  Yes you have to source for and build the wooden frame that holds the stators in place.  Detailed instructions are provided and the support from the ER Audio is superb to say the least.  This project is not for the novice DIYer, but the procedure to construct the kit is "foolproof".

I have contacted several owners that have built the kit, and all have reported outstanding reliability and support from ER Audio.  Performance of the ESL is equivalent or better than the ESLs commercially available today.  The completed speaker is adequated for a room up to 6m x 4m. It will go down to 35-38Hz @ -5/-6db.  Larger rooms would require some reinforcements.
 
The price of the basic kit (there is another more expensive and elaborate kit), by my standard is not cheap.  However there are some discounts when 3 kit or more are ordered.  I guess I am suggesting some form of group DIY, where we are able to share some of the costs and also help each other out during the build.

Before discounts, the price is AUD2062 for the kit and another AUD350 for shipping thru FEDEX.  If you are interested or have any queries please check in (reply to this thread).

[jasonlky]

I want to share my ESL build. The package arrived just after christmas and I stated the build almost immediately. This package is purchased from ER Audio of Australia. The kit is the ESL III which is a 3 panel design.... 1 treble panel sandwiched on either side by a full range panel. I placed the order about a month or so ago, Rob the owner sent the build manual, so it gave me plenty of time to get acquated in the build steps. I cannot say enough good things about Rob and Jan Mackinlay, they are both honest and helpful, eveready to offer advise and assistance at a moments notice.

Feel free to ask me any questions.

On to the build.

See pictures below.

Happiness is when a huge package is delivered undamaged by the courier. This box is huge and heavy.

[jasonlky]

After a brief inspection, averything was complete and in order. Nothing was damaged... perfect packing.

[jasonlky]

The next thing that caught my eye were the audio transformers. Humongous lumps of black iron. They were the heaviest items in the package. Here they are:

[jasonlky]

Further rummaging in the package revealed the CNC'ed support structures tucked at the bottom of the package. These support structures are made from plastic and milled on a CNC machine to generate the desired structure.  These support structures hold the stators and the diaphragm in place. Very well machined.

[jasonlky]

Close up of the CNC'ed support structures.

[jasonlky]

These are the Steel Grids that will be used as the the stators.  They are thin but sturdy and are finished in black powder coat.

[jasonlky]

Here I have the Support Structure and Stators laid out in a dry run to make sure everything fits.... and it does, perfectly.

The picture shows the narrower treble panels.  The white bottle, its the polyurethane glue used to attach the stators to the support structure.  The glue takes 24 hours to cure and is very very strong. Good stuff.

Also shown in the picture are wooden strips that will be used as pressure pads to ensure the support and stators bond perfectly during the curing process.

[jasonlky]

These are the Full Range Stators. They come with the terminal for electrical connection attached, see the little screw brazed to the bottom corner of each grid.

[jasonlky]

I finally start the build, the stators are laid out on a "production line" where the polyurethane glue is rolled onto them.

[jasonlky]

The Support structures are laid out on the table, ready to accept the stators once the glue is applied.  There are in total 8 full range panels and 4 treble panels to be glued.  So I do it in 3 runs of 4 each, thats 3 days of gluing, curing and waiting.

[yeo]

hi jasonlky

excellent work there! wow!  [smiley=thumbsup.gif]

for a while there, i was worried the most viewed thread (the diy esl project) will die a whimper. well, thanks to you, it's alive again!

keep the photos coming!

yeo

[vt4c]

Nice work!  :o

[KenC]

Hi,

Wow!!! how i wish I could have all the material packed and sent to me [smiley=evil.gif]!!! Looking forward to your next move.

May I ask why applying layers of PU glue on the metal stator? for insulating the panel?

Does the kit includes the diapharm tension gauge?

CHeer

KenC

[jasonlky]

Hi,

Wow!!! how i wish I could have all the material packed and sent to me [smiley=evil.gif]!!! Looking forward to your next move.

May I ask why applying layers of PU glue on the metal stator? for insulating the panel?

Does the kit includes the diapharm tension gauge?

CHeer

KenC

Hi KenC,

All you have to do is send your credit card to ER Audio and they will do the rest  ;).  My next move is to let the panels cure thoroughly and then attach the diaphragms.

PU on the stators.... serves 2 main purposes... 1. to glue the stators to the support structure; 2. to dampen the stator from vibrations and ringing as it is only 0.6mm thick.  The PU layer applied is very thin and the PU is applied over the entire surface on the non diaphragm side.  The diaphragm facing side is clean.  I cannot be sure of how well it will serve as a insulator.  

To answer your question, the kit does come with a tensioning gauge.  The technique used to tension the diaphragm is both unique and simple.  You will go "Why didn't I think of that"

You cannot believe how complete the kit is.... it even has the paint rollers to apply the PU, gloves to protect your skin as the PU is very strong.... to wire crimpers, all the terminals, wires and screws.  It has all that you will need to complete the kit except for the soldering iron, which is really optional and the enclosure to hold the completed panels.