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JULY 2025 UPDATE
JUNE 2025 UPDATE
BRAINSTORMING / PLANNING

JULY 2025 UPDATE

Updated order list:
- Driver (B&C 18SW115-4): $1057.08 CAD
- 2x Female Speakon Jacks: $35.42 CAD
- 2x Casters, Jack Dish & Gasket, ~3 ft Speaker Wire, 4x Corner Protectors: $58.11 CAD
- Acry-Tech Duratex Roller 1 US Gallon - Black Speaker Coating, Foampro 9" Refill Foampro 4" Roller: $194.07 CAD - 2x 18mm Baltic Birch sheets, 1x MDF: $365 CAD
Total: $1344.68 CAD

Pending:
- Inside Paint (Matte/Flat Acrylic Latex Paint & Primer?): ESTIMATE $50
- Misc Hardware, MDF, or Other Extras: ESTIMATE: $40
- Caster hardware: 4x 9 mm (0.35 in) Bolts? With Nuts?
- Corner protector hardware: 3x 4mm/0.16", ? long
- Jack plate hardware: 4x 5.2mm/0.2", ? long
- Jacks hardware: 4x M3 (or #4-40 close enough worst case?), 6mm or 8 mm long?, washers? nuts?
- Hardware for speaker: 8x 6.50min mm
ESTIMATE Total: ~$1740 CAD

Rest of the 3:
Drivers: $3194.46 CAD -> $1064.82 CAD each

Total Confirmed Cost Breakdown

Homemade sub setup:
- 4x Driver (B&C 18SW115-4): ($1057.08 CAD + $3194.46 CAD) / 4 -> $1062.89 CAD each
- 4x Total: $1740 CAD each

Off the shelf rest of speakers setup:
- POSSIBLE 4x Mid/High: ($1500 CAD * 4) / 4 -> $1500 CAD each

Electronics setup:
- POSSIBLE 1x OVERALL GRAPHIC EQ
- POSSIBLE 1x DSP (Crossover/Limiter/EQ) - VENU360 DBX DriveRack (cheap & maybe has in board mic for correction, but not enough outputs and maybe inputs) or XILICA XP-4080
- 1x Admark AD420: $1327.96 CAD + DUTIES/EXTRAS TBD
- POSSIBLE 1x Admark AD420, Admark K420, or other suitable amp
- POSSIBLE 1x Power Distro

Power Distros:
-

JUNE 2025 UPDATE

Speaking with my bassist friend who also happens to be a professional carpenter convinced me that I (we?) should prototype one xoc1 TH18 subwoofer before spending on all material for 4.
I ordered one B&C 18SW115-4 driver from ebay which all in came out to $1057.08 CAD.
Now I need to plan the rest of the materials.

*ALL TIMBER PANELS 18mm BIRCH PLY

**Panel Area Calculations (millimeters)**
Item No.	Description	Dimensions (W × H mm)	Qty	Area per piece (mm²)	Total area (mm²)
1	BASE	535 × 565	1	302,275	302,275
2	BOTTOM REFLECTOR	535 × 225	1	120,375	120,375
3	BACK	535 × 839	1	448,865	448,865
4	TOP	535 × 724	1	387,340	387,340
5	FRONT	535 × 460	1	246,100	246,100
6	BAFFLE	535 × 526	1	281,210	281,210
7	INTERNAL 1	535 × 478	1	255,530	255,530
8	INTERNAL 2	535 × 417	1	223,395	223,395
9	INTERNAL 3	535 × 240	1	128,400	128,400
10	INTERNAL 4	535 × 297	1	158,895	158,895
11	REFLECTOR 2	535 × 186	1	99,510	99,510
12	REFLECTOR 3	535 × 160	1	85,600	85,600
13	REFLECTOR 4	535 × 151	1	80,785	80,785
14	REFLECTOR 5	535 × 112	1	59,920	59,920
15	REFLECTOR 6	535 × 103	1	55,105	55,105
16	SIDE	724 × 1016	2	735,584	1,471,168
Total Area (mm²):					5,349,473
Total Area (m²):					5.35
Standard Sheet Area (mm²):					2,976,800
Sheets Required:					2

**Panel Area Calculations (inches)**
Item No.	Description	Dimensions (W × H in)	Qty	Area per piece (in²)	Total area (in²)
1	BASE	21.06 × 22.24	1	468.17	468.17
2	BOTTOM REFLECTOR	21.06 × 8.86	1	186.62	186.62
3	BACK	21.06 × 33.03	1	695.94	695.94
4	TOP	21.06 × 28.50	1	600.21	600.21
5	FRONT	21.06 × 18.11	1	381.68	381.68
6	BAFFLE	21.06 × 20.71	1	436.35	436.35
7	INTERNAL 1	21.06 × 18.82	1	396.31	396.31
8	INTERNAL 2	21.06 × 16.42	1	345.91	345.91
9	INTERNAL 3	21.06 × 9.45	1	199.05	199.05
10	INTERNAL 4	21.06 × 11.69	1	246.21	246.21
11	REFLECTOR 2	21.06 × 7.32	1	154.24	154.24
12	REFLECTOR 3	21.06 × 6.30	1	132.68	132.68
13	REFLECTOR 4	21.06 × 5.94	1	125.09	125.09
14	REFLECTOR 5	21.06 × 4.41	1	92.88	92.88
15	REFLECTOR 6	21.06 × 4.06	1	85.56	85.56
16	SIDE	28.50 × 40.00	2	1,140.00	2,280.00
Total Area (in²):					8,132.10
Total Area (ft²):					56.5
Standard Sheet Area (ft²):					32
Sheets Required:					2

TH18 Cut Fits Sheets 5ft x 5ft

Hardware & Extras Brainstorming:
- Casters:
-> "4 inch or 100 mm blue caster wheels from places like Guitel, Penn Elcom, Tente, Blickle"
-> CAD$14.52+tax+shipping x2 per build (https://www.penn-elcom.com/ca/100mm-fixed-castor-with-rubber-blue-wheel-w9004-v6)
- Pole Mounts
-> Too inconvenient to work into the build for the amount I imagine I would use them. Worst case potentially could add after the fact?
- Handles
-> Holes in the cab as handles in the top back and front forward corners should be sufficient (and lighter)
- Skids
-> Can't find any suggested models... some people just make them themselves. May be good to elevate with a skid or feet to protect the cab from the ground and the ground from the cab
- Metal grill (Home Depot? Amazon?)
-> https://metalsrus.ca/collections/carbon-sheet/products/carbon-steel-sheet-3-4-9-ex-meshraise-1497-x-cut-meshriase
-> https://metalsrus.ca/collections/carbon-sheet/products/carbon-steel-sheet-1-2-13-ex-mesh-flat-0897-x-cut-mesh-flat
- Jack plate
-> Adam Hall 87160 - Dish black for 2 XLR or Speakon Sockets
-> https://www.adamhall.com/shop/en/accessories-for-diy-speakers/87160
-> https://www.musicstore.com/en_US/USD/Adam-Hall-87160-Dish-black-for-2-XLR-or-Speakon-Sockets/art-PAH0006282-000?srsltid=AfmBOoqYuiqlw4pe2b7yUoReD7LeHdCx1MaQkH9Lyc3co0m-ssrAWqqF
-> https://www.thomannmusic.com/adam_hall_87160_einbauschale.htm
-> https://www.huss-licht-ton.de/product_info.php/en/Adam-Hall-87160-Mounting-Tray/info/12160.html
- Jacks
- Wiring
- Paint (DuraTex?? and Spray Paint?)
- MDF for templates for some pieces?

Mods to the design being considered:
- Extra handles? confirm
- Extra bracing in top back throat for resonance? confirm

I will need an amp to test the subwoofer once it's wired up.
Some options to keep in mind:
- Behringer iNUKE NU6000DSP (cheap all and one 3100 W x2 at 4 ohms?)
- Behringer iNUKE NU12000 DSP (cheap all in one 3400 W x2 at 4 ohms?)
- Behringer NX6000D? You get the point
- Admark K420 (3400 W per channel @ 4 ohms) - Pomelo sound uses this for their subs

I have also started looking at off the shelf mid/tops that could potentially match the type fo output from this subwoofer.
The most common and affordable option that is also trusted and powerful enough for the sub that I've found are the JBL SRX 725s.
They go for around $1500-$1600 each.

There are also the JBL STX825s.

Other findings:
- Power Distro

What’s a Power Distribution Box (Power Distro)?

A power distro is a piece of gear that takes in high-capacity electrical power (like 240V or 208V three-phase), and safely breaks it down into multiple circuits — usually standard 120V or 240V outputs — with circuit breakers, monitoring, and connectors suitable for pro audio gear.

🧱 Think of it like:

A heavy-duty power splitter + breaker box + surge protection, designed for concerts, festivals, clubs, or large A/V setups.

🛠️ Why You Need One

If your amp(s) can output 13,600W (like your 4×3400W setup), then:

You can’t run all that off one wall outlet.
A power distro allows you to:
- Pull high current safely from a big power source.
- Split it into multiple 15A, 20A, or 30A circuits.
- Protect each circuit with breakers.
- Monitor voltage and current in real time.
- Use pro-grade connectors like PowerCON, L6-30, or Edison.

🔌 Types of Inputs/Outputs on a Power Distro

🔲 Inputs:

Cam-Lok (for 100A+ 3-phase hookups at venues)
L14-30 or L21-30 (twist-lock, 30A/240V or 208V)
Hardwire terminals (for permanent installs)

🔳 Outputs:

Standard Edison (NEMA 5-15) 15A/120V outlets
L5-20 or L6-30 twist-lock 120V/240V
PowerCON or True1 connectors for pro audio gear

🎛️ Example Use Case

Imagine you're running:

2x amps, each pulling ~30A at 120V
1x DSP rack or mixer, ~5A
A few lights or fans

You could connect a 50A 240V line to a power distro, then:

Break it down into multiple 20A 120V circuits
Feed each amp on its own protected circuit
Monitor load to avoid tripping breakers

🏁 Popular Power Distro Brands

Furman (makes portable rackmount models)
LEX Products
Motion Labs
PowerWerks
ProX, AC Power, Middle Atlantic (rack-mount and budget options)

⚠️ Caution

Power distros deal with dangerous levels of current — get a licensed electrician if you're working with anything over a regular outlet.

For small setups, sometimes you can get by with multiple wall circuits — but once you’re above ~3000–4000W, a distro or 240V setup is safer and cleaner.

🎚️ Furman

These are known for being portable, rack-mountable, and great for small to mid-sized sound systems.

🔹 Rackmount models (15A–20A, good for small loads):

Furman P-1800 AR – voltage regulator + power conditioner
Furman P-2400 AR – 20A version with voltage regulation
Furman ASD-120 – 6-circuit sequenced power distro (20A per circuit, total 120A split)
Furman CN-2400S – Smart Sequencing, 20A

🔸 Note: These aren't big show distro boxes — more suited for racks or medium rigs.

⚡️ Lex Products

Lex is used in touring, festivals, and industrial-grade applications. Their stuff is robust, often rubberized.

🔹 Portable Touring Distro Boxes:

Lex PowerHouse™ Portable Distribution Box (100A or 200A versions)
Lex Bento Box – compact stage distro (20A to 50A)
Lex EverGrip™ Feed Thru Boxes – modular options for stage and event use
Lex Slim Distro – narrow-profile for small setups

🧳 Motion Labs

Very common in pro touring and AV production. They often build custom distro racks, but also have standard models.

🔹 Common Motion Labs Models:

MLAB 3-Phase Rack Pack – customizable, typically 100A or 200A input
MLAB Socapex Distro Boxes – stage or truss power splits
MLAB Combo Distros – split large amperage to 20A and 30A branch circuits
Mini Distro Series – compact, 1U to 3U rackmount units

🧰 PowerWerks

Great for North American users needing rugged mobile distros — often used in DJ, club, and mobile sound reinforcement setups.

🔹 Models:

PowerWerks 30A Rackmount Distro – L14-30 input with 6× 15A/20A Edison outs
PowerWerks 50A Spider Box – 50A California-style input with 6 circuits
PowerWerks L21-30 Distro – 3-phase 208V input, 6× 20A breakers (for bigger venues)

🎛️ ProX / AC Power / Middle Atlantic

These are often more budget-conscious or rack-focused — great for smaller setups or venues.

🔹 ProX:

ProX X-PD1000 – 100A distro, rackmountable
ProX X-PD3000 – 3-phase distro for large touring systems

🔹 AC Power:

AC Power 120V Rackmount Distro
AC Power 50A 240V Spider Box

🔹 Middle Atlantic:

PD-915R – 9-outlet rackmount (not a full distro, more for rack gear)
PD-920R – similar, with surge protection

🧭 Summary Table

Brand	Model Example	Input Type	Output Circuits	Use Case
Furman	ASD-120	Hardwire/120V	6x 20A	Medium rack or small tour rig
Lex	PowerHouse 100A Distro	Cam-Lok	6–12x 20A+	Large-scale touring/festivals
Motion Labs	Rack Pack 3-Phase	Cam-Lok/Custom	12x 20A or Socapex	Full pro A/V, modular setups
PowerWerks	30A Rackmount Distro	L14-30	6x 20A Edison	Mobile DJ / mid PA rigs
ProX	X-PD1000	100A Cam-Lok	6+ breakers	Budget-friendly tour distro

- Home Use Cargo Vans:
-> Chevrolet Express
-> GMC Savana
-> Ford E Series (E-150, E-250, E-350)
-> Dodge Ram Van
-> Ford Transit (Expensive/Not Quite Right?)
-> Ram Promaster (Expensive/Not Quite Right?)
-> Nissan NV (Expensive/Not Quite Right?)

Build Videos For Building Reference:

BRAINSTORMING / PLANNING

Soundsystem Inspiration

Toronto:

Funktion One at Apollo events (notably by Athan Ioannidis)

Montreal:

Void at Expose Noir events (notably by ?)
Danley by Elastique Audio

Goal

Soundsystem that is:

Extremely Powerful
Portable
Efficient
Expandable
"Home" or "Unprepared" Grade Power Requirements
"Affordable"

While audio power can be achieved with many speakers, this may not be very portable (or easy to store).
Also, while audio power can be achieved with less speakers by supplying more power to the speakers, this may not be feasible with the available non-commercial electricity.
Therefore, need a speaker design that can provide the most power for the least amount of drivers and efficient amplifiers (minimal heat loss).
Also, it would be useful to have a system that could be expanded and added onto over time. A passive speaker solution with central amplifier allows this easily and allows for easier powering and control from a central unit.
A passive speaker setup also allows for separation of the "hardcore" electronics (amplifier) from the more resistant speaker boxes (solid cabinets with speakers and speaker wire to a jack panel).
While amplifiers are better left to the pros, rigging speakers and cables to a jack panel in a wood enclosure is a realistic DIY project.
However, I would want to avoid just making any rough or improvised cab and experimenting through trial and error - a well proven design will already have the efficiency people count on from the off the shelf product.

Off the Shelf Speakers Cost

As of January 2025, 1x Danley TH118: $4789 USD or $6875 CAD + tax

	Price(w/out tax)
1x TH118	$6875
2x TH118	$13750
4x TH118	$27500
6x TH118	$41250
8x TH118	$55000

Speaker Build Costs

1x XOC1 TH18 (Danley TH118 "Clone"):

B&C 18SW115-4 Driver: $684 USD or $980 CAD + tax - Revision: $1060
Wood: ?????? (Assuming $500) - Revision: $300
Accessories: ?????? (Assuming $300) - Revision: $100

TH18 with Reflectors & Material Cutlist

TH18 On Speaker Plans Website

Example Build With Good Accessory Mentions

Example Build Pics

Realistic Example Build Pics

Realistic Build With Talk About Handles

Build With Suggestions For Other Plan Built Mids and Highs

	Price(w/ tax)
1x XOC1 TH18	$1780 (Revision: $1460)
2x XOC1 TH18	$3560 (Revision: $2920)
4x XOC1 TH18	$7120 (Revision: $5840)
6x XOC1 TH18	$10680 (Revision: $8760)
8x XOC1 TH18	$14240 (Revision: $11680)

Amplifier Costs

I still have lots of research to do about suitable amplifiers as well as budget friendly amplifiers.
However, cost permitting, a Linea Research amplifier seems ideal. Assuming 1x TH118 or XOC1 TH18 is 3400 W,

	Max Watts (Subs)
1x XOC1 TH18	3400W
2x XOC1 TH18	6800W
4x XOC1 TH18	13600W
6x XOC1 TH18	20400W
8x XOC1 TH18	27200W

Plan

4x Xoc1 TH18 (B&C 18SW115 Drivers)
4x Cubo Kick 15 (? Drivers)
4x Highs (Homebuilt could be MT-130, SMT 212, MT 121, MTH 30)

raw_wood_2x_th18_cubo15_mt130

For first iteration, highs can be off the shelf (Yorkville, QSC, JBL, Turbosound, etc.)

If after a year or more of use of this system has at least paid it off, then can think of expanding by doubling it.