I have been hearing a lot about the Radio Shack 40-1354 fullrange driver. It sounds like a good way to build some inexpensive and simple speakers, which is exactly what I wanted for my workshop. I opted for a simple ported design, despite a recent fascination with the TQWT.

As with most stamped-frame drivers, anything that can be done to stiffen the suspension should be a good thing. I have always been fascinated with PC-7 epoxy, and thought this would be yet another use for this amazing stuff. I filled the gap between the frame and the magnet with it and smeared some on the "spokes" of the frame also. I have not A/B'd this modification, so I can't say whether it has helped, but it seemed like a good idea :)

So what is this with the plumbing pipe, you ask - well, if you are ever in need of some port tubing and don't want to order it online, just run down to your local hardware store and buy a length or two of "Flanged Drain Pipe" or something like that. This stuff is about 14 inches long and has an inside diameter of 1.375 inches. The O.D. is 1.5 inches, so you can use your handy-dandy 1.5 inch hole saw to make the holes for it.

My favorite binding posts are plain old 10-32 brass thumbscrews and bolts. They are cheap and they tend not to strip as easily as most gold plated binding posts. Of course they are not insulated, so you will need to look elsewhere if you need posts for a metal chassis.

Update [2002-02-03]:

Not quite happy with the treble coming out of these babies, I installed a motorola horn tweeter. I crossed it over with a 110 ohm resistor across the terminals and a 0.022uF orange drop inline with the positive terminal. This would appear to cross it over above the audible range, but in parallel with the piezo - which has some sort of strange impedance - it is just right. The tweeter is in phase with the fullrange. Driven by my 6v6hifi amplifier, imaging is fabulous. Finally I have a system that presents the soundstage from speaker to speaker. I am experimenting with Dammar to tame a little honkiness in the low treble, but otherwise I am quite happy with the little fellas.