DIY metal speaker grills (1 Viewer)

[Steve Hanna]

I want to make grills that won't cover up my too cool IMHO speakers, be acusticly transparent, and protect from my six curious cats and future grandchildren. I thought I'd post this info and let you look it up and comment on the possibilities. I'm partial to the 3/4" crimped wire as it would look good either black or chrome plated. That hex hole looks pretty good, easier to fabricate, and it's cheaper too.
So what do you think?
Go to http://www.mcmaster.com
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Hexagon-Hole Perforated Sheets
Material has a staggered hole pattern. Sheet size is 36" x 40". Alloy 3003-H14 aluminum is lighter and more corrosion resistant than steel.
Center-
Hole to-Center Open
Thick. Ga. Dia. Spacing Area Each
1008/1010 Cold-Rolled Steel
0.030" 22 1/4" 9/32" 79% 92725T22 $22.43
Alloy 3003-H14 Aluminum
0.032" 20 1/4" 9/32" 79% 92725T42 34.58
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Crimped Wire Cloth —This cloth has crimped wires to secure them in place. Crimping assures rigid and accurate screen openings. Material can be used for machine guards, barriers, shields, and dividers.
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Heavy Duty Crimped Metal Wire Cloth
Opening Wire 36" x 48" Sheet 36" x 60" Sheet 48" x 48" Sheet 48" x 60" Sheet
Size Dia. Each Each Each Each
Plain Steel
4" 0.250"
9327T131 $31.54
9327T161 $39.43
9327T221 $42.06
9327T271 $52.57
3" 0.250"
9327T132 40.11
9327T162 50.14
9327T222 53.49
9327T272 66.86
2" 0.250"
9327T133 54.86
9327T163 68.57
9327T223 73.14
9327T273 91.43
2" 0.192"
9327T137 42.51
9327T167 53.14
9327T227 56.69
9327T277 70.86
2" 0.135"
9327T139 33.26
9327T169 41.57
9327T229 44.34
9327T279 55.43
2" 0.120"
9327T141 31.54
9327T171 39.43
9327T231 42.06
9327T281 52.57
1 1/2" 0.135" 9327T142 41.83
9327T172 52.29
9327T232 55.77
9327T282 69.71
1 1/2" 0.120"
9327T143 39.77
9327T173 49.71
9327T243 53.03
9327T283 66.29
1" 0.135"
9327T144 57.60
9327T174 72.00
9327T244 76.80
9327T284 96.00
1" 0.120"
9327T145 54.17
9327T175 67.71
9327T245 72.23
9327T285 90.29
3/4" 0.120"
9327T147 64.46
9327T177 80.57
9327T247 85.94
9327T287 107.43
Galvanized Steel
2" 0.120"
9327T341 48.00
9327T361 60.00
9327T371 64.00
9327T381 80.00
1 1/2" 0.120"
9327T342 59.66
9327T362 74.57
9327T372 79.54
9327T382 99.43
Type 304 Stainless Steel
2 x 2• 0.120"
9327T621 61.71
9327T641 77.14
9327T661 82.29
9327T681 102.86
2 x 2• 0.250"
9327T624 180.00
9327T644 225.00
9327T664 240.00
9327T684 300.00
3/4 x 3/4• 0.105"
9327T626 114.86
9327T646 143.57
9327T666 153.14
9327T686 191.43
Aluminum
2" 0.250"
9327T411 97.71
9327T431 122.14
9327T451 130.29
9327T471 162.86
1 1/2" 0.120"
9327T413 52.80
9327T433 66.00
9327T453 70.40
9327T473 88.00
1" 0.120"
9327T415 59.31
9327T435 74.14
9327T455 79.09
9327T475 98.86
• Mesh per inch.
Crimps between the intersecting wires make the wire cloth more rigid and the spacing more accurate. Plain steel is a low carbon material, making it an economical choice where corrosion is not a concern. Galvanized steel has a bright coating of corrosion-resistant zinc. Type 304 stainless steel has greater chemical corrosion resistance than galvanized steel. Aluminum is lightweight and corrosion resistant.
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[Greg Monfort]

The wire mesh needs to be as thin as practical and have openings small enough to prevent little fingers from intruding, but large enough for 20kHz to pass through (amazing how much better a horn driver sounds after you've cut out the 3? micron mesh bug screen stretched across its throat), so from a quick browsing I choose 0.0173" dia. galv. steel wire mesh cloth with 0.225" spacing stretched over a frame. Since plating will increase wire thickness, a misted coat of lacquer to spruce it up would be my choice if any coloring is required.

GM

 

[Brandon B]

Also keep in mind, one good impact to the aluminum hex hole material, and your grill's looks are trashed. Upside is you could get it anodized black or brown and add almost nothing to its thickness.

BB

 

[Steve Hanna]

You've got a good point there. At least the wire mesh is more resilant and will restore back easier. It can be painted any color or plated with chrome etc. I think 3/4" will keep the cats and small fingers from hurting large woofers. Pencils will penetrate almost any barrier however.

The tweeter on my B&W CDM1 has a fine steel mesh cup screen protecting it. As for grill defraction issues, at what F does it start to be an issue with tweeters and midrange drivers?