On Saturday, we traveled to my house (within easy driving distance) to execute the prototype build of the project. We chose to leave Drexel's campus for a few reasons. First, having access to a car would allow for easy purchase and transport of necessary bulk materials (PVC, plywood, etc.). Also, it allowed for the flexibility of running out and buying more material easily if unforeseen building issues may have come up. Finally, my house had the necessary woodworking materials and space for construction, without having to work around the schedule of the Machine Shop and the other implicit constraints that would have accompanied that route.
Throughout the past week and half, each group member had been working on a different iteration of the stand design. These were modeled using the Fusion 360 software, which itself was chosen due to its ease of use and for its collaborative/cloud features.
Preliminary CAD Designs
1. Simple Uni-columnar Design - Nick
This design features a single 3" PVC segment as the primary structural component of the stand. PVC Toilet flanges allow for a secure transition from the vertical plane (pipe) to the horizontal plane (top/bottom). The rectangular plates at the top and the bottom will consist of 3/4" plywood. This thicker plywood was chosen because it provides the necessary depth to screw the flanges into the plate without breaking the surface of the wood itself. It will be filled with sand to add weight.
2. Uni-columnar Design with Triangular Base - Blake
This design was the result of several iterations of playing with the advantages and disadvantages of altering the plates from a simple rectangular shape to a variety of other geometric forms. Ultimately, the triangular base was chosen due to its ability to be leveled rather easily on a uneven surfaces. With legs at each of the corners, it functions almost as a small tripod system. The other specifications are similar to Nick's uni-columnar design.
3. Quad-columnar Design - Gabe
Gabe sought to explore the advantages and disadvantages of changing the number of pillars that function as the structural component of the stand. Differing sizes of PVC (2", 1.5", 1") also had to be experimented with, which the CAD was extremely helpful with. Ultimately, after much debate and research, a 4 column, 1.5" PVC design was decided upon due to its ability to provide a strong base with enough volume to weigh down with sand.
Ultimately designs 1 and 3 were chosen as the designs to be prototyped. Design 2 was simply too close to the first design, and didn't offer enough benefits (other than aesthetic) to justify its construction as well.
The Build
Stand 1:
The construction of this stand was relatively easy. The pipe was cut to size (21") with a miter box and attached to the flanges securely with PVC primer and glue. The pipes were filled with sand and 1" wood screws were used to attach the pvc portion to the wood plates, which were cut to exactly hold the speaker. These wood plates were made using a table saw to create a plank of wood to the necessary width (8"), and the other (9") dimension was obtained using a circular saw. All assembled, the stand is 24" tall, bringing the speakers to an optimal height (seated ear level).
Stand 2:
This stand required some more precision in construction. After wresting for many hours over the best method for attaching the PVC columns to the plywood plates (ideally a flange would exist to fit over a 1.5" PVC, but the toilet flange is obviously designed for a specific purpose and only comes in 1 size). After research, we were able to locate and purchase a quick-setting epoxy that would bind PVC to wood, and while not an ideal method, this was by far the best option for accomplishing that task. However, this also required that each of the four columns were exactly the same length, or the flat board would not sit firmly atop it. Therefore, this required care in both measurement and cutting to produce the identical pipe sections, depicted below. Once completed, these pipes were first glued to the bottom plate, then filled with sand, and finally attached to the top plate in a similar fashion. Before transportation back to school, the epoxy was giving an hour to fully cure.




Initial Reactions:
First impressions with the stands have been extremely encouraging. The raising of the speakers off of ground level provides a noticeable improvement in sound, and the stands have proved to be more than acceptable in terms of rigidity and weight. Hopefully, these improvement will be able to quantified during the testing that will occur this week.