Build Log
Behind-the-scenes documentation of our system builds, upgrades, and testing. Watch the AG Audio rig evolve.
Entry 13: First Event — Free Rave at The Bunch of Grapes
On the 30th of August, the sound system made its debut in a real-world setting with our very first event at The Bunch of Grapes, Newcastle Emlyn. The aim was simple: host a free rave to showcase the system, gather a crowd, and begin creating a name for ourselves in the local scene. The build was fully deployed, with the complete speaker stack and amplifier rack set up on-site. The outdoor/indoor hybrid space provided a dynamic testing ground for coverage, power handling, and audience interaction. Highlights from the night: The system delivered clean, high-output sound across the venue, impressing attendees with bass depth and clarity in the highs and mids. Crowd feedback confirmed that the mixing desk and DSP settings translated perfectly to a live performance environment. The event atmosphere validated all months of design, fabrication, and tuning, showing that the system could handle extended play at high volume without compromise. The free event strategy successfully drew attention, helping establish the collective’s presence in the local electronic music scene. This first event marked a pivotal milestone: the transition from build and testing into live performance, proving both the reliability and impact of the custom sound system in a real-world setting.
Entry 12: First Mix & Outdoor Test
We moved to a real-world evaluation: our first full mix on the sound system. The setup was assembled in the garden, creating an open-air environment to truly challenge the enclosures and DSP tuning. A small group of friends attended, providing live feedback on tonal balance, imaging, and overall impact. Tracks spanning multiple genres were played at varying volumes, from moderate listening levels to near-peak output, putting both the hardware and DSP settings to the test. Observations from the session: Highs were crisp and well-dispersed across the listening area Midrange clarity allowed for vocals and melodic elements to cut through without harshness Bass and kick drivers delivered deep, tight low-end that remained controlled even at high output System coherence and stereo imaging were impressive, maintaining balance even in an open-air setting This outdoor session not only confirmed the robustness and fidelity of the build but also highlighted minor refinements for future EQ and delay adjustments. Overall, it was an exhilarating validation of months of design, fabrication, and assembly, and a milestone moment for the project.
Entry 11: Initial System Testing
The sound system underwent its first full operational test. The goal was to verify functionality, ensure driver protection, and assess acoustic performance before live deployment. Testing procedure included: Power-On Checks: Gradual voltage ramp to confirm all amplifiers and drivers powered without issues. Signal Verification: White noise, pink noise, and sine sweeps were played through each channel to confirm correct routing and polarity. Frequency Response Assessment: Measurements taken with a reference microphone at multiple listening positions to verify crossover accuracy and band integration. Level Testing: Drivers were incrementally driven up to nominal operating levels, observing thermal and mechanical limits. Horn and Bass Alignment: Fine adjustments to delay and EQ ensured coherent imaging and smooth low-to-high frequency transition. Observations: All drivers responded correctly with no audible distortion at reference levels. Bass and kick channels delivered tight, controlled low-frequency performance. Horn-loaded highs were clear, well-dispersed, and balanced across coverage area. Patch panel routing and amplifier configuration proved reliable and intuitive for setup. The successful initial test confirmed the build integrity, wiring accuracy, and DSP configuration. Minor tweaks to EQ and delay were noted for final optimization in a live environment, marking the system as operational and ready for its first real-world application.
Entry 10: DSP Configuration & System Tuning
This stage focused on digital signal processing (DSP) setup and system tuning. Each driver band was assigned to its corresponding amplifier channel, and initial crossover settings were applied based on manufacturer specifications and system design. The tuning process involved: Configuring high-pass, low-pass, and band-pass filters for each driver type Adjusting delay, phase, and polarity to ensure coherent summation across the frequency spectrum Applying EQ to compensate for room acoustics and enclosure characteristics Verifying system protection settings, including limiting and thermal safeguards Test signals were played through the system to measure frequency response, output levels, and transient behavior. Minor adjustments were made iteratively to achieve smooth frequency coverage, proper crossover integration, and balanced tonal response across the full range. Once tuning was complete, the sound system demonstrated its intended high-output performance, precise imaging, and reliable operation—ready for deployment in live and studio environments. This entry marks the transition from build and assembly to operational testing and real-world use.
Entry 09: Amplifier Rack & Patch Panel
Attention shifted to the system drive infrastructure. A dedicated amplifier rack and patch panel assembly were built to provide organized signal routing, protection, and reliable deployment in live use. The amplifier rack was configured to house the system power amplifiers along with power distribution and signal management components. Equipment layout was planned to balance weight, maintain airflow, and allow clear access to front-panel controls and rear connections. Patch panel fabrication involved installing chassis connectors into a rack-mounted panel to provide robust external I/O and simplify system setup. All internal rack wiring was loomed and strain-relieved to ensure durability during transport and operation. Rack build elements: Power amplifiers mounted and secured Mains power distribution installed SpeakON output connectors assigned per band (HF / Mid / Kick / Bass) Input XLR connectors routed to amplifier channels Internal signal and speaker wiring loomed and labeled Each output was mapped to the corresponding loudspeaker band to match the cabinet wiring scheme, allowing quick and error-free system connection in the field. Continuity and polarity checks were performed across all patch points and amplifier outputs. This stage completed the system drive rack, enabling integrated connection between processing, amplification, and the loudspeaker stack, ready for crossover configuration and full system testing.
Entry 08: Hardware Installation & Wiring
The enclosures progressed to final hardware installation. All drivers, horns, and mounting hardware were prepared and checked prior to fitting to avoid damage to the finished surfaces. Each component was installed into its corresponding routed aperture, ensuring flush seating against the baffle rebates. Mounting holes were aligned and fastened using appropriate bolts and threaded inserts to provide secure, serviceable fixing capable of handling high SPL vibration. Installation sequence: Compression drivers mounted to HF64 horns Horn assemblies installed into HF baffles Mid-range and kick drivers fitted and torqued evenly Bass drivers installed into low-frequency enclosures Internal wiring looms routed and secured Internal wiring was completed using heavy-gauge speaker cable, with polarity verified across all drivers to maintain correct phase alignment. Connections were terminated and strain-relieved to prevent movement or fatigue under operation. Upon completion, all cabinets were fully loaded with the drivers, ready for initial testing.
Entry 07: Cabinet Coating
A durable textured speaker coating was applied to provide mechanical protection, moisture resistance, and the characteristic professional finish expected of touring-grade cabinets. Before application, all surfaces were wiped down to remove any remaining dust. Coating was then applied evenly across all external faces, working into edges and routed features to ensure full coverage and consistent texture. Coating process: First coat applied Drying period observed per manufacturer specification Second coat applied to build uniform texture and durability Visual inspection under angled light to confirm coverage The resulting finish produced a tough, impact-resistant outer shell while maintaining the clean lines of the cabinet geometry. Once fully cured, the enclosures were ready for hardware installation and final system integration.
Entry 06: Sealing & Surface Preparation
All external seams and minor surface imperfections were inspected and filled where necessary to ensure airtight cabinets and a uniform exterior. Internal cabinet joints were sealed with acoustic-grade sealant along all panel interfaces and brace contacts. This step eliminates potential air leaks and improves low-frequency efficiency and overall enclosure performance. External preparation included: Filling screw holes and panel seams Sanding all cabinet surfaces to a consistent finish Breaking sharp edges and refining roundovers Final inspection of panel transitions and flatness Progressive sanding passes were carried out to remove machining marks, adhesive residue, and filler transitions, resulting in a smooth, paint-ready surface across all cabinets. Dust was thoroughly removed prior to finishing to ensure proper coating adhesion. At completion of this stage, all enclosures were structurally sealed, cosmetically uniform, and fully prepared coating.
Entry 05: Dry Assembly & Glue-Up
Each enclosure was first dry-fitted without adhesive to verify panel alignment, joint accuracy, and internal bracing placement. This step confirmed that all routed rebates, brace notches, and mating edges seated correctly and that the cabinet geometry matched the CAD model. Once satisfied with the fit, final assembly proceeded using high-strength wood adhesive applied to all mating surfaces. Cabinets were built in a controlled sequence to maintain squareness and ensure internal structures were correctly positioned before enclosure closure. Assembly process highlights: Internal braces installed and clamped into position Side panels and baffles aligned and fixed Clamps applied across all axes to maintain pressure and prevent gaps Excess glue removed along seams prior to curing Each cabinet was left clamped for the full adhesive cure time to achieve maximum joint strength and structural rigidity. After curing, clamps were removed and joints inspected for uniform seams and air-tightness. This phase completed the structural build of the enclosures, with all cabinets now fully assembled and ready for sealing, sanding, and finishing preparation.
Entry 04: Routing & Driver Rebates
With all cabinet panels cut to size, the next stage focused on machining the functional features required for driver mounting and final assembly. Using the CAD drawings as reference, centre points and cut diameters for each driver aperture were transferred onto the relevant baffle panels. A router with circle jig was used to cut the driver openings, ensuring perfectly round apertures matched to each component’s specified cutout diameter. Rebates were then machined so the driver frames would sit flush with the baffle surface, providing proper acoustic loading and a clean, professional finish. Additional routing operations included: * Horn throat openings and mounting bolt patterns * Access panel recesses * Internal brace notches and alignment features * Edge roundovers where specified in the design Test fitting was carried out with each driver and horn to confirm tolerances, bolt alignment, and seating depth before moving on to cabinet assembly. All routed panels were lightly sanded to remove machining marks and prepare bonding surfaces. This stage completed all precision machining, leaving the full panel set ready for dry assembly and glue-up.
Entry 03: Measurements & Cutting
A delivery of 10 sheets of Latvian birch plywood arrived, selected for its high density, strength, and acoustic stability—ideal for loudspeaker cabinet construction. Using the cut plans generated from the CAD models, each sheet was carefully measured and marked out to maximize material yield while preserving grain orientation and structural integrity. Layout lines were transferred directly onto the boards, ensuring all panel dimensions and angles matched the digital templates. Panel cutting was then carried out in two stages: * A jigsaw was used to rough-cut the larger cabinet panels from the full sheets. * A table saw was used for the smaller, precision cuts and to bring panels to final dimensions with clean, straight edges. This phase produced the full set of cabinet panels, accurately sized and ready for routing, driver cutouts, and assembly preparation.
Entry 02: Hardware Acquisition
Suppliers were researched to ensure authenticity, availability, and reliable delivery of professional-grade components. Orders were placed through established pro-audio retailers including Blue Aran and Thomann. Driver and horn selection followed the original system specification, prioritizing high efficiency, power handling, and compatibility with the modeled enclosures and horn profiles. Particular attention was given to matching compression drivers with the HF64 horns to achieve the intended high-frequency dispersion and output. The chosen components represent top-tier, touring-grade hardware suitable for high-output sound system use. Hardware List : 2 × RCF HF64 — Constant Directivity Horn 2 × BMS 4555 — High-Frequency Compression Driver 2 × Precision Devices PD.121/2 — Mid-Range Driver 2 × Precision Devices PD.154/2 — Kick Driver 2 × Void V18-1000 — Bass Driver All items were successfully procured and inspected on arrival, confirming model numbers, impedance ratings, and physical condition prior to integration into the build.
Entry 01: Speaker Cabinet Design & Modeling
The project kicked off with acquiring the original schematics for the speaker cabinets. These provided the baseline dimensions, internal chamber volumes, port geometry, and panel thicknesses required to maintain the intended acoustic performance. With the schematics in hand, the first major task was to translate the 2D plans into accurate 3D models. Each cabinet was carefully recreated in Fusion 360, ensuring all critical measurements matched the source drawings. Internal features such as bracing, driver cutouts, and port paths were modeled to verify clearances and structural integrity before any material was cut. This modeling phase allowed us to: * Confirm overall enclosure volume and tuning * Check fitment for drivers and hardware * Visualize assembly order and joinery * Generate precise panel layouts for cut plan Completing the CAD models established a reliable digital reference for the build, reducing risk of material waste and ensuring consistency across all cabinets moving forward.
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