The Fairchild Ghost. Subwoofer project.

DJ_Bucho · 29 Jul 2025 at 23:49

Absolutely superb, loving the look of this and the detail that you're going into sourcing each individual part, brilliant. Out of interest what are the "silicon end splitter things" actually called, as I've been on the lookout for some of those for some of my cables, but could never find any.

ALXAndy · 30 Jul 2025 at 11:07

DJ_Bucho said:
Absolutely superb, loving the look of this and the detail that you're going into sourcing each individual part, brilliant. Out of interest what are the "silicon end splitter things" actually called, as I've been on the lookout for some of those for some of my cables, but could never find any.

I dont remember lmao.

Currently sat on phone waiting for deliveries but when I jump on the laptop I'll DM you directly to them.

ALXAndy · 30 Jul 2025 at 16:57

OK so the final work day on this visit. I am off home on Friday, but need to tidy all the tools away tomorrow. The next job will be the grille. Routing out the hole for the speaker, magnets etc. For now though I put the last outer panel on.

And then stood it up. Note, I masked inside the terminal holes to try and keep dust out when I get to the sanding and filling stage.

The front.

I then removed the failing protective plastic on the perspex.

And then masked it. If you are wondering why I masked inside? well dust will get in there when I cut the hole for the speaker and the gasket only runs around the outside. So I envisioned getting a load of crap in between the perspex and baton.

This also arrived. It is a lot bigger than I thought. It will still work, but I need to mount it differently.

DJ_Bucho · 30 Jul 2025 at 23:17

ALXAndy said:
I dont remember lmao.

Currently sat on phone waiting for deliveries but when I jump on the laptop I'll DM you directly to them.

Superb, thanks very much

ALXAndy · 31 Jul 2025 at 10:50

No worries man. I was happy to find those as Chord wanted £15 for two /roll eyes. So today it is mostly tidying things away. Will measure up the VU meter for the various plates I need to CNC but yeah, mostly getting the place tidy. Am off home for a week for a rest. There would be no point hanging on because the weather is poo and the next stage for the cabinet is outside and sanded to within an inch of its life. And filling and more sanding etc.

ALXAndy · 31 Jul 2025 at 14:05

Jumped into the design earlier and knocked out all of the parts I need to do the VU meter.

And then in black.

ALXAndy · 5 Aug 2025 at 13:36

OK so the bit that didn't fit was sent back, amended and then returned.

So I will build the woofer at the weekend.

ALXAndy · 8 Aug 2025 at 16:49

OK, back.

And build !

I used blue loctite in the end. Get out the 5 minute epoxy, and.

Then just a lil bit of 3M

I will be woodworking tomorrow, but I also started sorting out the VU

All of the parts are here now, including the power socket and plug. I then made up the cable that will go into the VU when it is built.

I also had a small problem. Due to the Medite's outer casing being harder the counter sink bit (which could do with being sharper) left burrs around the outer edges of the holes. This is annoying because I did not want to have to do tons of sanding before I fill. That is also why I abandoned the front holes half way through as I realised this. So, I got this.

And it already paid for itself because the lower spider clamp was too tight and it was jamming, so I had to drill it out +0.5mm and then deburr it. Yet another tool I should have bought years ago.

Righto, off to design the CNC magnet covers.

ALXAndy · 8 Aug 2025 at 17:31

OK so the magnet cover plate will be made out of black and gold. The base black lower part..

And then a gold top plate cover.

ALXAndy · 9 Aug 2025 at 17:14

OK so today did not go as planned. My arthritis was awful and so I did not want to operate the router. I still got loads done, though. First I deburred every screw hole on the cabinet, then put in the first round of filler.

And then set up the drill press. I can now use it with an indicator that lets me know how deep I have gone. It is also nice and straight and level.

ALXAndy · 10 Aug 2025 at 13:42

Mornoon.

Just thought I would post to say I just pooped my pants.

I set up the CNC and left it to its own thing about 20 mins ago. I then put on my new headphones (Dyson Zone, brand new £150). They were a bit poo at blocking out the noise. However, I realised I had never activated the noise cancelling. The noise is literally gone. I then thought maybe I had snapped the bit, as things were too quiet even with music off. Nope !. Panic over, I had not snapped the bit, these headphones are just amazing at blocking out noise. Sheesh !

You shall hear from me later this arvo. When I should have a mostly assembled VU. No point even trying to do anything tool wise today as my aunt came over to help mum in the garden so it was off limits.

ALXAndy · 10 Aug 2025 at 14:48

Grr. Jinxed myself. The bit did actually snap but not when I thought. I just didn't hear it go because of the headphones

sake. Still one part is finished so I have just chucked some more perspex down and set it back to work. I did notice the bit was a bit sticky and old, should have changed it.

ALXAndy · 10 Aug 2025 at 16:04

Another one bit the dust. No idea why, it was brand new and I even slowed the feed rate down. Had to use a larger bit, so no doubt will get punched when I go downstairs as it is quite noisy (understatement of the year). Have ordered some 1mm bits. Hopefully that will be the sweet spot between noise and etc.

ALXAndy · 10 Aug 2025 at 18:25

OK so bloody finally after 3 set ups ffs.

I will wire it tomorrow.

Even though it was a ball ache it was almost worth it. Love how nice and compact it is.

ALXAndy · 11 Aug 2025 at 14:59

OK so update coming in later.

I forgot to say I finally got rid of the skin condition. Finally found the right cortisone. Any way, as you lot may have noticed it's a bit warm today eh? I envisioned myself sweating over a cabinet with a sander in my hand, then realised it hasn't arrived yet lmao. It is coming tomorrow. As such I set up the machine last night for the magnet cover, and have finished cutting the gold part. I am now cutting the black one. I think in this heat sitting in front of a fan watching it work is about bob on tbh. That said all jokes aside I have been pussy footing around the CNC and as thus jobs were starting to stack like crazy. With this magnet cover done the woofer will be 100% complete and there is only one label badge left to do. Which is ace, especially as it is stupid hot here.

ALXAndy · 11 Aug 2025 at 17:24

Sorted.

ALXAndy · 12 Aug 2025 at 16:39

So the grille is done. This was *a lot* of calculating, head scratching and so on. Everything was going to be tight, and I also needed to bear in mind where it would sit on the cabinet and where the woofer would go.

I routed the hole out. It took ages. Like, far longer than I ever thought it would. That tool to me is terrifying. Loud, obnoxious and sounds like it is about to blow up. I got there in the end. I then put it under the drill press and pre drilled all the way through. This will then allow as a jig to drill the magnet centre holes in the box, and, show me where the woofer needs to be fitted. I've also sanded it ready for paint etc, but tomorrow I will use it as said jig to mark out the cabinet.

ALXAndy · 13 Aug 2025 at 14:07

OK no manual labour today. Knee went out yesterday and I can barely walk. It also said it was going to rain, not ideal. So I gave myself a day off. Meaning the CNC is now running carving this for me.

I also need to draw and carve some cover plates for the DSP. So yeah, no time wasted and I can rest up.

ALXAndy · 14 Aug 2025 at 14:26

OK so not off to the best of starts today. Woke up at 6am in agony. My entire left upper arm was burning and numb. Seems I either got stung by a wasp, or bitten by a spider. Either way the little chuffer had made its escape so I didn't get to squash it. I don't do too well with stings and bites, so my arm is now painful and a bit numb. Not tool condition, that's for sure. As such I have revised one of the CNC jobs I wasn't that pleased with and am running that now.

Talking of which.....

I have wanted to further upgrade my machine for ages. I already put the bigger rails and bed on making it a 3040, but the motor is a bit jank also. So I wanted to go brushless. Problem is as you look around the machine you start to realise its a bad idea. The motor holder now is plastic, the controller can't do a brushless motor nor has power for it, the steppers are weak, it does not have limit switches or a stop button and etc etc etc.

As such I found this one. It 100% does alu. Brushless 500w motor, manual knobs which would be very handy and all of the things mine would need. I can just bolt it straight onto my bed, which is awesome, and would allow me to replace the brass bearings which are now quite worn.

It's £260. About half of what I would pay for it all in parts. Will probably order than when I come back over.

Cenedd · 14 Aug 2025 at 16:01

It's not the motor power that will mean it can/can't do aluminium. My mini mill is also 500W brushless and that will run a 10mm endmill a few mm through steel. The issue is the rigidity of the frame since it is easier to bend out the way than cut the metal. That and your spindle is probably set up for high rpm - which you need for smaller endmills and engraving bits. 10k or 20k is not uncommon. Mine will do maybe 2k rpm.