Cornscala?

UPDATE Oct. 7 2012

Please click on one of the 5 styles of Cornscala on the left side of this page to see the current offerings.

Style A:  Uses the CT125 tweeter, M2380 midrange horn, Selenium D405 midrange drive and CW1526C woofer.  The CT125 is flush mounted from the front and all other parts are mounted from the back.

Style B:  Uses the CT125 tweeter, M2380 midrange horn, Selenium D405 driver and CW1526CF woofer.  All components are flush mounted from the front on the Style B.

Style C:  Uses the Selenium D220TI tweeter on the Selenium HM11-25 horn, Selenium D-405 on the M2380 horn and the CW1526CF woofer.  All of the components will be mounted from the front. Originally, we planned to use the Selenium HM4750 horn on this version, but mounting the horn with the amount of recess necessary was a problem.  And without recessing it a lot, a grill becomes really impractical.  So, we will just use the M2380 with does not have that problem. 

Style D:  A 2-way version.  Uses the Faital HF140 HF driver on the Faital LTH142 horn with the CW1526CF woofer.

Style Original:  Thought we might as well offer the one that started this Cornscala project off.  This will have the K-401 horn, CW1526CF woofer CT125 tweeter and Atlas PD-5VH midrange driver.  


What Is a Cornscala?

It is not a Klipsch speaker, but was inspired by a couple of different Klipsch speakers.  I own lots of speakers including 3 pairs of Lascalas and a pair of Cornwalls.  Used to drive me nuts listening to Lascalas and to Cornwalls alternately.  I loved the top end of the Lascala, but did not like the fact that the Lascala has no ability to produce really low bass.  Just about nothing there below 50 hz.  Now, the Cornwalls excel in the bass area with good solid lows down into the 30s, but with the small midrange horn, something always seemed lacking in the higher frequencies.  Just not as open and clear sounding as the Lascala.

OK, the Lascalas are fully horn loaded and therefore are extremely efficient.  About 104 db at one watt.  The Cornwall is efficient, but not that efficient.  About 100 db at one watt because the bass is a direct radiator.  That is the trade off we have.  And there is always a trade off.   In the Lascala, we give up really low bass in exchange for efficiency.  In the Cornwall, we give up some efficiency for really low bass.

I mulled over those differences for quite awhile and finally decided to try to merge the Lascala and Cornwall into a box.  I really did not know how this would sound in the end, but I needed a "test speaker" in the shop anyway.  I wanted to be able to quickly put in a tweeter or a mid-range driver after a repair to give it a quick listen and thought at least this project could be used for that.  

I figured the size of the bass bin to be a cube of 24 inches per side (outside measurement).  That yields an internal volume of 22.5 X 22.5 X 22.5 = 11390.6 cu. in. or about 6.59 cu. ft. or about 186.6 liters.  It is ported in the front with about 50 square inches of port.  The shelf forming the top of the port extends back 9 inches from the motor board and is placed 3 1/4 inches above the floor of the cabinet.  I had a local cabinet shop build the cabinet out of 3/4 inch MDF.  The motor board just extends up above the bass bin enough to install the K-401 midrange horn and a tweeter.  The first of these I built actually has cutouts for 3 tweeters.  That was to allow me to use switches to switch between two tweeters to see how well they match.  Remember, part of the reason for building the first one of these was to be able to quickly and easily test repaired drivers.

A few pictures.

Bass Bin

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Bass Bin With Motor Board

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This thing sounded so good that I almost immediately had another cabinet built so I could have a pair.  This time without the extra tweeter slots.

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Back of Motor Board

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Motor Board installed on Bass Bin Back View.

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Front View

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So, there you have it, the Cornscala.  I have all the parts to build these except the midrange horns.  For those, you would have to find a used pair of Klipsch Metal K-400 horns or buy from Klipsch a pair of new composite K-401 horns.  You can perhaps find a rough set of Lascalas to use to get most of the parts, or a set of Cornwall 1s.  Cornwall 1s would have all the parts except the crossovers and midrange horns.  Lascalas would have all the parts except the crossovers.

If you want to build these with all new parts, I can provide those parts (except for the midrange horn).

Pair of CW1526C Cast Frame Woofers $265.00

Pair of CT125 Tweeters  $160.00

Pair of Atlas PD-5VH Midrange Drivers $275.00

Pair of Cornscala Crossovers $210.00 (This is the original on a 6 X 10 cedar board which is meant to mount inside the cabinet and have input wires going from the input terminals on the back of the cabinet to the crossover.)

Pair of NEW STYLE Cornscala Crossovers  $240.00


CORNSCALA II

Not being one to leave well enough alone, I starting thinking again.  I wonder if I could get all that in one box to clean it up a bit.

OK, we are not going to get that K400/K401 horn in any reasonable size box, so the search started for a horn that would fit the box.  Wanted the biggest one I could get in there.  The Pyle Pro PH-2380P would just fit.  So, that project started.

Pictures..

Cabinet is same as a Cornwall except the motor board has different size cut out for midrange horn.  Had these made out of cabinet grade Maple plywood.

Here is a drawing of a Cornwall cabinet.  This would have all the information needed to build the Cornscala II cabinet except the details for the cutouts on the motor board.  I suggest that the person building these first obtain the woofers, midrange horn and tweeters so the motorboard cutouts can be made accurately using the actual drivers and horns for the pattern.  

Cornwall Cabinet Plans


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Motorboard

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Drivers and horns installed

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Another with motor board installed

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Cornscala II ready to rumble

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Works very good and could be dressed up with your choice of nice finish.  Too bad, Pyle discontinued the midrange horn shortly after I discovered it.  Now the PH-800 horn I used in place of the Pyle Pro horn has also been discontinued.  We are testing more horns now (March 1, 2010) and hope to soon have another suitable horn available.

UPDATE ON MIDRANGE HORNS

Still working on this (March 6, 2010).  I have a promising horn and driver.  The horn is a Selenium HM4750SLF and the driver is a Selenium D405.  This is a 2 inch horn and driver.  Testing looks like it is a good match and good for a replacement for the K-55 or Atlas PD-5VH and any of the horns that have been used so far.  You can see information on these in the Selenium section of this website.

Still am working on finding a good 1 inch horn also.  I am supposed to have one to evaluate soon.

UPDATE March 14, 2010

I am ready to say that the Selenium D-405 is a good driver to use in a Cornscala.  I have in a couple of weeks of listening and testing on these drivers and I think they sound very good.  The typical crossover we have been making for the Cornscala II just needs a small mod to work with these drivers.  So, as a list, the following parts apply.

Pair of CW1256C Cast Frame woofers $265.00

Pair of CT125 Tweeters $160.00

Pair of Cornscala crossovers $210.00  (This is the original on a 6 X 10 cedar board which is meant to mount inside the cabinet and have input wires going from the input terminals on the back of the cabinet to the crossover.)

Pair of NEW STYLE Cornscala Crossovers $240.00

Pair of Selenium D405 2 inch midrange drivers $348.00

Pair of Selenium HM4750SLF 2 inch inlet horns $220.00

OR Pair of M2380 2 inch horns $130.00

Pair of support brackets for the M2380 horn and D405 driver.  $10.00

To talk a bit about these two horns, they sound the same to me and test the same.  The M2380 is a copy of the JBL 2380 horn.  The main difference between these two horns is the mounting flange.  The M2380 is a "flat face" horn with about a 1/2 inch thick flange.  It needs to be flush mounted with the front of the motorboard, so that will require it to be mounted on some sort of "doubler" from the back that extends it through the front to be flush with the front.  Or, you could make the motorboard out of thick enough material so that it could be front mounted recessed into the motorboard.  Since no one has built a Cornscala using this horn, this will be something to be worked out.

The Selenium horn is made to be front mounted only.  It has some "lips" that protrude from the front about 1/2 inch, which will make installing a grill somewhat more difficult.  Add the thickness of the flange and you would have to allow about 3/4 inch distance from the motor board to the grill fabric. 

To continue this a bit, the D405 driver weighs about 18 pounds.  I have had it on both of these horns with the horns mounted on a motorboard.  Everything seems plenty sturdy mounted like that, but I would feel better if the driver was supported from the back. The Selenium horn comes with a bracket meant to be used between the driver and horn as a support.  The M2380 horn does not come with a bracket.  The maker of the M2380 seems to think it does not need a support for the driver.  That may be right.  I think I will see about getting a local shop to fabricate a bracket suitable to support the M2380 horn in case some may want it.

UPDATE April 12, 2010  

I now have the horn and driver support brackets for use with the Selenium D405 and M2380 horn.  Those will be $10.00 per pair.

Driver Support Bracket

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 UPDATE April 28, 2010

Some have wanted a gasket to place between the bracket and horn or driver and horn.  Or just if you need a gasket for a 2 inch driver, I had some made.  These gaskets are 2 inch ID and 3 inch OD and 1/16 inch thick made of red rubber.  These are $2.00 per pair and shipping in the US of $1.00 by 1st Class Mail.  If ordering other parts, I can just put these in with the other parts for no increase in shipping in most cases.

2 Inch Horn to Driver Gasket.

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UPDATE May 18, 2010

I have seen the first pictures of a set of these using the new 2 inch midrange driver and horn described above.  Rick gave me permission to show these on here.  I think he did a great job on these and he reportedly is enjoying the sound.

Rick used the CT125 tweeters, Selenium D-405 2 inch midrange driver, M2380 2 inch midrange horn, CW1526C cast frame woofers and the CSS 500/5000 crossovers. 

He has worked out a neat way to support the massive D405 driver as shown here:

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Closer view of the support.

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And of the woofer, port and crossover:

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Front:

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Very nice work Rick!

UPDATE on Rick's Cornscalas OCT. 31, 2010

Rick took a break from listening to his new Cornscalas long enough to finish them.

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Those look great Rick!

UPDATE Sept. 6, 2010

Another set of Cornscalas completed.  These are in Australia.  John chose to use the Selenium D220Ti driver on the Selenium HM17-25 horn for the tweeter.  He used the Selenium D-405 Driver on the Selenium HM4750-SLF horn for the midrange.  CW1526C woofer.

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John also built three of our CS-1 speakers to round out this project nicely.

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Good job John!


UPDATE Sept. 14 2010


 Australia has another set of Cornscalas.  Leo used the Selenium D405 with M2380 horn for the midrange, CT125 tweeter, CW1526C woofer and our CSS500/5000 crossover.  I think Leo plans for these to be gloss black when finished.

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Bracing the cabinet and supporting the midrange horn and driver.

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Back

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Front

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UPDATE DEC. 4 2010

Leo has sent a picture of his Cornscala with the gloss black finish:

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Good Job Leo!


UPDATE  Sept. 24 2010


Another set of Cornscalas are born.  Doug may hold the record on how quickly a set was completed to the stage of making music.  I sent him the parts last Monday, FOUR days ago.  Doug used the Selenium D405 with M2380 horn for the midrange, CT125 tweeter, CW1526C woofer and our CSS500/5000 crossover.

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Another innovative way to support the heavy D-405 driver.

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Doug still has some finishing work to do on these, but like most of us, he got to the point where he could hear them and just had to pause there for some listening.  Good work Doug.

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Oct. 3, 2010  Doug did not let those stay rough very long.  Here is the finished product.  Nice work!

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April 17, 2011

Latest Cornscalas I have pictures of.  These were built from a set of cabinet parts we sent and are the Style B using the CW1526C woofers, Selenium D-405 driver with the M-2380 midrange horn.  CT125 tweeter and our CSS500/5000 crossover.

Nice work Woody!!

Speaker #2 internet

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April 20, 2011

These were build in Italy, I think about a year ago.  Roberto did some mods to put the crossover outside the box and some other interesting innovations like moving the woofer up like is done on the Cornwall III. This pair uses the CT125 tweeters, Atlas PD-5VH midrange driver with PH800 Horn and the CW1526C woofers.  The crossover is the CS500/4500.  

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Very nice work Roberto!!


B & K Sound, 1925 East Gum Log Rd. Russellville, AR, 72802 phone-479-967-1542