Zigmahornet speakers are tall, narrow speakers that only use one driver each. They look like they shouldn't work at all and yet they're really quite good. The sound is surprisingly full and satisfying.
I needed a couple of speakers with a small footprint to go into my office and I figured I'd try out this project. I'd first read about them on 6Moons and it looked fairly straightforward so I jumped on in.
My apologies for the lack of process shots. These came together over several mini-sessions in the shop and my friend's garage and I often didn't have a camera on me at the time.
Many thanks to diyaudioprojects.
Step 1: Materials and Tools
- One sheet of 1/2" birch plywood
- Wood glue
- Table saw (or Home Depot if you're nice)
- Miter saw
- Hole saw
Step 2: Cutting Into Strips
Attached to this step is the SketchUp file I created for these speakers. This is based off of this diagram. I highly recommend downloading SketchUp both because it's a tool you should check out and it's very helpful here to see it in 3D.
Since these speakers are tall and narrow, you're going to need some clean long cuts for the four vertical pieces. That makes four lengthwise cuts at 4 3/4" and four at 2 7/8".
One option, the best way, is to use a table saw. We didn't have that option easily available so I got it cut at Home Depot where I bought the plywood. Normally, they'll only do a couple of cuts for you, but we convinced them to run all of our vertical cuts for us.
Step 3: Cutting the Pieces Down to Size
What's important here is not only cutting the pieces to the right length, but also cutting them at the correct angle.
2 7/8" wood
4 side pieces - with a 45-degree cut at one side. One side of the wood will be 54 15/16" long and the other will be 57 13/16"
4 3/4" wood
2 front pieces - 53 1/2" long with a 67.5-degree bevel cut
2 back pieces - 58 5/16" long with a 45-degree bevel cut
2 top pieces - 5 1/2" long with a 45-degree bevel cut on one side and a 67.5-degree bevel cut on the other
3 3/4" wood
Trim 2 feet of the 4 3/4" wood down to 3 3/4"
2 vertical pieces - 3 1/4"
2 horizontal pieces - 1 3/8"
Step 4: Inside Pieces
The two smallest pieces will be going inside and all you need to do to get them ready is glue into an L shape like the picture below.
Step 5: Front and Sides
This time we'll be gluing the front and sides together and the inner L pieces from the last step. Get out your clamps!
The front piece will line up with the side pieces at the top and should be 1 5/8" shorter at the bottom.
Step 6: Add the Back
With everything set, glue the back piece on.
Step 7: Cap the Top
Use a combination of wood glue and finish nails to securely attach the top.
Step 8: Attach a Base
For the base, I used a piece of scrap plyboo that had a 3-inch margin around the body of the speaker. You should have plenty of plywood left over for this, though. Attach with more glue and a few screws.
Step 9: Cut Speaker Holes
With a hole saw cut out holes for the speakers to go into. The center of the holes should be 19 5/8" from the top of the speakers.
You will also need to cut a smaller hole in the back for the terminal cup.
Step 10: Finishing It Up
Now you get to choose your stain and color your new speakers. Apply a few coats of stain and then a few coats of polyurethane and you're good to go! Insert the speaker wire, drop in the speakers and listen to some music!