[OnEdge]

It’s great to see your back at it!

[tobycj]

I will have to remove these later to paint the MB, but they fit well. I will also drill a third hole behind the power cell mount to add a third bolt between the two, to provide more accuracy to what is seen on screen.

I will likely drill and tap a hole for a very short screw just for aesthetics.

The powercell bracket was riveted in place, rather than using screws

[edspengler]

Thanks for that input on the rivets, I may or may not go for it as it would be nice to have the mounts be easily removable… but I might change my mind. For now I just used some button heads that I happened to have on hand, this isn’t final.

[edspengler]

I am brainstorming the options for audio. I am leaning towards using 3 speakers:

5x7 in the cyclotron
1 inch tweeter in the top area
4 inch mid in the top area

These would all be joined using a 3-way crossover. The current GBfans board has two stereo outputs, I am thinking I would have to run both outputs into a mono converter that would feed the crossover. Could potentially run an external amp before the crossover like I did with my spirit but that would also require a line out converter… which i have on hand. I guess i would test this setup first without the additional amp to see how loud it is.

I would appreciate any thoughts or suggestions.

I was considering 2 5.25 inch speakers in the cyclotron but from research I have concluded that they would be too close together and the sound may not be as clear. Also the different sized speakers with crossover would provide an excellent range (in theory) for all the sounds the pack makes.

Edit: I purchased a 6.5” woofer (for under the cyclotron), some 1” tweeters, audio crossover, and a stereo to mono converter. I have a 4” mid already on hand. I’ll set everything up this weekend and hopefully it is a success.

[Mike3042]

Any way you can post some side profile shots of the installed GBFans injector tubes? I have the same tubes and since they are 1 1/4" dia instead of the correct 1 1/2" dia, I want to see some more photos of what they look like installed...

[edspengler]

Got to prototype my audio setup and it sounds AMAZING!! I got a dud for a stereo to mono converter so I ordered a new one, I had to test the setup out of a single channel of the board so the sound effects themselves were a little wonky (files are stereo and not mono). Everything is crystal clear at full volume with no distortion at all.

Rather than install speakers directly into the board, the crossover distributes the audio signal amongst the proper speakers - bass to the woofer, mid to the mid, and highs to the tweeter - meaning all the speakers work together. Ordinarily single speakers have to work too hard to produce all the ranges at once and can distort at high volume… not this setup! Also I have to say the improved amp on the newer GBfans board powers this setup incredibly well.

Edit: I just plugged this speaker setup into my scaled spirit pack that is outfitted with the older (mono audio) GBfans board and a 100W additional amplifier and the volume is unreal.

This is my original spirit build:

Additional amp connected to the older GBfans board:


Connecting this amp into the crossover (board on my desk) yields incredible sound. However this amp does not play well with the newer GBfans board as it generates distortion (works perfectly with the older board with a line out converter).
The spirit pack unfortunately may be gutted and rebuilt at a later time… in the name of science!!

Here is a sample of Haunted House on unbearably loud volume hooked up from the spirit pack 100w amp, the audio setup balances the highs and lows wonderfully with no distortion at very high volume.


The only drawback to this design is if you run it at the insane volume it will eat through the battery faster than the typical setup. Given the crazy volume will not be used too often, I can live with this tradeoff.

[edspengler]

Any way you can post some side profile shots of the installed GBFans injector tubes? I have the same tubes and since they are 1 1/4" dia instead of the correct 1 1/2" dia, I want to see some more photos of what they look like installed...

[edspengler]

A bit more brainstorming on how all the audio equipment will actually fit. The intent is to mount everything to the MB, but I need to see how it would actually fit in the shell. The boards will likely be stacked on risers to conserve space. This is the overall idea:


Audio board, amp, crossover, and a few other bits and bobs. Not to mention the smoker relay too, but stacking the boards using risers should solve that. I may also go for a more powerful tweeter… as there is more depth available under the vac line.

I am also considering mounting the crossover and amp at 90 degrees to add more space:



Overall this system is so loud that you I would not be able to wear it at high volume without ear protection. But that’s what a pack should be

[edspengler]

Here is a demonstration of the audio system that will go into this pack, it has the capability to be incredibly loud which is perfect for outdoor events. I would not wear it at high volume without ear protection. I continue to speak after turning it on so you can hear the volume relative to my voice, in this video it is at approximately 1/4 volume which is a lot indoors.


I am also brainstorming how to fit this all into the pack. So far my plan will be to cut an acrylic plate to mount all the electronic boards to - the electronics will not be directly mounted to the MB. Two reasons for this, if I ever want to change the electronics I can mount to a new plate and not change the mounting points in the MB. Also, a plate will hide a lot of the wiring and it will look cleaner.

I cut a paper pattern for now to determine the plate shape as well as experiment with how everything will fit, so far so good.


I also received my vintage straights in the mail today, the first picture shows the fitting next to the reproduction that I was previously using followed by more pictures of the fittings and installed on the shell.


So far I have been able to secure a good number of vintage parts, progress!

[edspengler]

My goal was to mount all the electronics to an acrylic board, which I was having trouble cutting. I finally had some luck! After drawing my pattern on the board again, I scored the cut lines with a knife to help guide the dremel cutting wheel. I used the 90 degree attachment to be able to have better control of the cutter relative to the surface and it worked!


Next came overlaying all the various PCBs as I had previously done with the cardstoxk pattern to drill mounting and cable holes. Took some time to do it carefully, but this also worked fine.


Next mounting all the boards and making sure it fits as intended.




Test fit


And finally a test of the arrangement to make sure it all works.


This took me a good several hours to get done but I am really happy with it.

Well I took a break and came back! I decided to take the plunge and finally mount the setup to the MB. I used blue painters tape to hold it in place while placing the shell, had to repeat a few times using trial and error to find exactly the right spot for it to fit. I used a marker to mark the holes, center punched, and then drilled using a step bit. Here are the results!



I feel like I have cleared a major hurdle in the project. Of course I’ll have to remove everything to paint the MB, but it will be easy to reassemble.

[edspengler]

A few minor updates. I am waiting for a new low profile subwoofer to arrive, the speaker I was using to fill this roll is too tall and I feel it could have more bass, it is labeled as a midrange. I scoured the net and was able to find a subwoofer that is actually that, and will meet my size requirements.

Also, my electronics setup results in bolt locations in the MB that are not “accurate”. I have decided to countersink these holes so that once planted they will appear to be flush - except for under the power cell. I will be ordering a countersink bit set to address this.

Then it will also be time to cut speaker holes in the MB, I have a few ideas but still have not decided on a hole pattern.

[SP Productions]

Great progress! Enjoying your build!

Sean

[edspengler]

I received the new subwoofer today and it is absolutely phenomenal. It is an actual woofer versus using a larger speaker to channel the lower frequencies. The bass is deep and rich and will only sound better with the shell applied.


It compliments the mid and tweeter perfectly.

[edspengler]

I am brainstorming between two options for the subwoofer and trying to weigh each option before I proceed.

1. Cut a 6.5” hole in the MB behind the cyclotron and mount it from the outside and place a protective screen over it. Pros: it will give the surface optimal movement and will offer a little more clearance under the cyclotron. Cons: May not look as nice, but I could get a nice grill.

2. Mount the subwoofer on risers and drill a hole pattern in the MB as a speaker grate. Pros: May look a little cleaner? Cons: the configuration does not provide optimal air movement for the subwoofer and it will be a tighter fit possibly rattling other components. Here is how it would appear mounted on risers:



I was contemplating building or buying a small box for the subwoofer, this could be more possible if the large 6.5” hole is cut… but the cyclotron portion of the shell will also act as a box once assembled - and the speakers are as far apart as possible.

I’d appreciate any thoughts or suggestions.