Zeppelin 1x8 Cabinet Assembly Instructions Manual Download

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Summary of Contents for 1x8 Cabinet

Page 1: ...SPEAKER CABINET ZEPPELINDESIGNLABS COM 2950 N WESTERN CHICAGO IL 60618 Assembly Instructions 1x8 SPEAKER CABINET KIT...

Page 2: ...ILL 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 TOGETHE...

Page 3: ...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 fin...

Page 4: ...arefully 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 do...

Page 5: ...5 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...

Page 6: ...8 1 TM02 Paper templates 2 In Hardware Bag Part Description Notes Qty CB11 Zip Wire 16 2 6 2 FT03 Foot x 4 J2 1 4 Mono Phono Jack Female Input 1 JA07 1 4 Mono Phono Jack Male Cable 2 NU03 Tee Nut 8 32...

Page 7: ...7 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...

Page 8: ...o 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 i...

Page 9: ...first drill through with the 9 64 bit then countersink with the bit carefully and gradually adjusting the depth of plunge until the full diameter of the bit just barely cuts into the wood The screw sh...

Page 10: ...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 8 Use the pencil to mark the four screw holes on the Port 9 Put...

Page 11: ...DGE of the wood and center it along the length of the wood Don t worry about the REAR edge 5 With the awl or a nail and small hammer carefully poke a hole into the wood at the center of each cross hai...

Page 12: ...t in from the edge of the side 18 Place the cleat with the nail marks facing up Use the same port piece to space the cleat down from the end of the cabinet side 19 Note the cleat is cut a little short...

Page 13: ...ide so you can put it back in place later 22 Set the cleat aside 10 Repeat steps 7 9 for the remaining three cleats 23 11 Re drill the eight pilot holes in the cleats with the 9 64 bit and countersink...

Page 14: ...OUTCOME Place the screw tips into the mating pilot holes in the cabinet side 27 13 Grab your screw gun fitted with a NEW 2 Philips driver and the clutch set low press down hard and drive the two scre...

Page 15: ...eces of wood as carefully and accurately as you can Be sure the faces the sides touching the table are flush to each other at the joint 32 If the parts are a tiny bit uneven on the back face that is t...

Page 16: ...5 Drill a total of 8 holes 20 Disassemble the four pieces Still with the 1 16 bit drill four blind pilot holes about deep in the Bottom where marked36 and four holes deep around the Port jack hole 37...

Page 17: ...sides as before with the front edges down on the table Apply some wood glue to one end of the TOP Smooth the glue out until it uniformly coats the end 24 Fit two wood screws into the appropriate two...

Page 18: ...hard and drive the two screws barely snug 45 You will tighten these later Note you are setting these screws into end grain and it may need a lower clutch setting than you used on the cleats to preven...

Page 19: ...remaining exposed ends of both the TOP and BOTTOM Fit four screws into the remaining SIDE and maneuver them into all four little pilot holes Align clamp and screw the joints barely snug one at a time...

Page 20: ...ker you will have to remove the baffle from the front which weakens the rigidity of the baffle See REPLACING THE SPEAKER It really depends on how likely you are to want to try lots of different speake...

Page 21: ...1 8 deep through the ports where marked and into the cleats 60 33 Re drill the four port holes with the 9 64 bit61 and countersink62 Be careful not to drill into the cleat Whether gluing the ports or...

Page 22: ...baffle and inspect the joints If any joints are poorly mated or if the ports stick out of the back of the cabinet grind them flush with 60 grit sandpaper 65 36 Edge Detail If you want to apply a rout...

Page 23: ...a vacuum or compressed air and inspect the seams between the Sides and the Top and Bottom 68 If there are any gaps you cannot live with fill them with wood dough Allow the wood filler to harden thorou...

Page 24: ...s harder more stable and more durable than pine It is the wood of choice for all fine millwork that is destined to be painted but properly prepared it stains nicely too 1 If you did not glue the ports...

Page 25: ...t least not for the inside edges sand the square edges by hand only The orbital is likely to chew up the inside corners c Sand the two exposed faces of the ports and ease the edges 73 Be thorough The...

Page 26: ...he inside corners 76 78 There is no point in trying to stain the inside of the hole in the port 5 Now wipe the stain off again with a large clean rag 79 Rub it out thoroughly and carefully leaving no...

Page 27: ...ately do NOT apply poly to the ENDS of the ports They will get along fine without it but if you do poly them they will have a hard time fitting back in to the cabinet Set the cabinet back down on its...

Page 28: ...finish 9 Apply a second coat of Wipe On Poly to the exterior Allow to dry thoroughly 88 10 At this point if the box is beautiful and satiny smooth you are done If it is still a little fuzzy or uneven...

Page 29: ...board Part BB08 with masking tape 89 Line up the outside edges as best you can 90 2 Use the awl or hammer and nail to mark the locations of the four 9 64 holes near the corners of the board 91 3 If ne...

Page 30: ...four holes in the corners of the board If you have a drill press use it Otherwise take care to hold the drill as straight up as you can Hold the baffle firmly down against a piece of plywood or a smoo...

Page 31: ...to put on the grill cloth Attaching grill cloth in a way that looks nice is not an easy task There are two goals to keep in mind in working with grill cloth 1 keep the lines straight and 2 make the g...

Page 32: ...r line and crease it the entire length of the grill cloth The bent edge should be at a 90 degree angle b Place the baffle board back on the grill cloth with the edge against the fold and center the bo...

Page 33: ...is parallel and closest to the the other side of the baffle opposite the first fold Remove the baffle board and cut the grill cloth along the previously folded crease to this new parallel line 106 Onc...

Page 34: ...oles Alternatively if you own a Percolator 2 Watt Tube Amplifier by Zeppelin Design Labs orient the cloth to match the pattern on the amp grill While holding the baffle board black side and t nuts dow...

Page 35: ...f each side and move to the corners 113 Alternate sides with each staple Put the staples in at a 45 degree angle so that all the staples aren t lined up in the middle of the edge 114 If any staples ar...

Page 36: ...ner of the baffle board hold both corners of the grill cloth down one of top of the other Use your razor to cut a 45 degree line through both layers of cloth from the corner of the baffle board Remove...

Page 37: ...asily the grill cloth is affected by your heat gun Start with the heat gun on the lowest setting and if that isn t hot enough you can move up from there Also start with the heat gun at least 12 away f...

Page 38: ...ly Also be careful not to press down too hard on the screw as you tighten it otherwise it might push out the t nut from baffle board Leave it slightly loose 20 Repeat for the remaining three screws an...

Page 39: ...N Solder fumes are not healthy for you The fumes consist of vaporized flux which can irritate your nose lungs and even your skin You MUST work in a space where the air drifts away from you as you work...

Page 40: ...the terminals 132 Place the ribbed wire in the hole of the negative lug the one attached to the barrel of the jack The wire should be placed in the hole from the inside rather than the outside examine...

Page 41: ...areful to solder the ribbed wire to the negative terminal the one marked with a 139 Solder the wire with writing on it to the positive terminal marked with 140 Also be careful not to drip molten solde...

Page 42: ...you The fumes consist of vaporized flux which can irritate your nose lungs and even your skin You MUST work in a space where the air drifts away from you as you work so fumes do not rise straight onto...

Page 43: ...ers carefully open the crimp ring at the rear of the jack 145 4 Mount the jack in some sort of clamp vise or fixture with the solder terminals exposed 146 5 Tin the two contact points on the jack as s...

Page 44: ...lug 150 152 7 After the lugs have adequately cooled carefully squeeze the crimp rings back down onto the wire 153 This should be snug enough to hold the wire in place but not so tight that you damage...

Page 45: ...der connections make sure they are sound and secure and that there are no stray strands of wire loose anywhere Fix it now 13 Test the continuity of the cable with your multimeter Set your meter to the...

Page 46: ...It s what connects the load the speaker to your amp Most amplifiers especially tube amps are very particular about what kind of load they are powering so it is very important that this cable is funct...

Page 47: ...h a scrap of wood Be sure they are seated as tightly as possible 2 Use the screw gun to drive four 6x1 1 4 wood screws Part SC61 through the ports and into the cleats 3 Install the feet using the four...

Page 48: ...ers 7 Remove the baffle and use the 1 16 bit to drill four pilot holes about deep into the cleats 165 8 Drop the baffle back into place careful to place it in the same orientation as previously 166 9...

Page 49: ...plate over the port hole lining up the mark on the plate with the mark on the cabinet 169 170 12 Use the four 4x5 8 sheet metal screws Part SC65 and the small straight screw driver to mount the jack p...

Page 50: ...ou may be interested in experimenting with changing some things about your cabinet One of the easiest tone mods you could perform on your cab is to change the speaker We have chosen this Jensen speake...

Page 51: ...rews from the front and remove it that way We recommend rear service because we do not want you to run the baffle screws in and out of the cleats more than necessary It is important for this connectio...

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Zeppelin 1x8 Cabinet, Assembly Instructions Manual

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