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  #1  
Old 09-20-2010, 01:56 PM
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Default superior tweeter packaging

I had to pack up a brand new pair of tweeters due to it's original box being collapsed and frankly, just not stout enough.

I started with a 7"x7"x6-1/2" usps flat rate box,...

and a cpl strofoam ends layin around from a new sump pump that I installed.


The styro fits nicely with 1/2" of play on 2 sides.



I filled the void in one styro end with packing peanuts, flipped it upside down, and filled the rest through the broken flap.





(more coming,...)
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Old 09-20-2010, 02:10 PM
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I had some 1/2" closed cell foam cut into 3-1/2" strips that filled in the gap left over, I just held it to the top of the box and made a snip at the bottom corner with a pair of scissors to mark my length.

note that one side will be 1/2" smaller than the other.





got a nice even shoulder for the next piece of styro to fit against on top of the first.



nice,.. It sits just 1/2" below the top of the box.

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Old 09-20-2010, 02:25 PM
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I like this.

I have thought of doing write-ups about packaging but I haven't the time.
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Old 09-20-2010, 02:25 PM
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next, I cut a template using 2 strips of foam with scissors to fit into the remaining void.

I got the shape I needed an placed the foam inside the styro,.. I then used a 2" holesaw (sans mandrell) to cut the slots out for the flush mount cups and off-axis mounts.

turning it counter clockwise is the latter direction seeing that the teeth on the saw dig in making it a real pita to turn it clockwise.





now that they're cut, I can use them to trace my next 2 pieces of foam for the tweets and other off-axis mount.

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Old 09-20-2010, 02:47 PM
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I put the next pieces under the first ones and used the holesaw again with the upper layer as a guide.





with the leftover slugs that were cut out, I stuffed them in the flush mount cups.



they fit in very securely along with one of the angled months.
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Old 09-20-2010, 02:54 PM
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and the next layer over that.



one tweeter,..



sorry for the sideways pics, I can't rotate them in editing from my phone.

two tweeter,...

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Old 09-20-2010, 03:49 PM
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for the final internal layer, I took one strip and laid it across both tweeter motors and cut what I thought was round off the sides and two reliefs for the hardware.



after that was cut, I turned it over and used a 1-1/2" holesaw to cut halfway into this layer, followed with cutting out what needed to be removed with a utility knife.





and slots for the wires.



there we go,..

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Last edited by Nudels; 09-20-2010 at 03:52 PM.
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Old 09-20-2010, 04:06 PM
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very nice
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Old 09-20-2010, 04:27 PM
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for the hardware, I just filled the reliefs I cut earlier, made a plug to secure one bag.



and just placed the other 2 bags on top of the off-axis mounts.



after that, I cut 2 layers of rolled thin wall foam to fill in any leftover space.



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Old 09-20-2010, 04:54 PM
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last was to fill in the remaining voids, 2 strips cut to length for the walls as done previously, but I cut off the excess using a utility knife that I ran sideways into the foam along the top of the box,...





and 2 more for the top.





viola!,.. Done!



using this type of foam will work very well for any piece of equipment that you want to go overboard protecting from the unforseen clumsy delivery service/worker. You can layer it with many reliefs cut out to conform to just about any shape while being limited only by your imagination.

I hope this tutorial gives ppl the ambition to thwart possible damaged goods,..

I know this won't get hurt
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