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DIY - 212 cabinet - help with ports calculation

Absolutely, recessing is part of the finishing and that's how a typical grill is installed.

Why don't you look and see how other designers (successfully) do this? It seems like you are working really hard to reinvent the wheel, without realizing the the wheel has already been invented.

I was not intended to reinvent the wheel. I was played on messa boogie power house 212, i like it sounds ok. I started some research and found that faital speakers are used as replacement in some messa boogie cabs. I don't know if that's true but found that some people successfuly assembly 212 cabs with faital pro with good results. I ordered driver for 60% of price brand new.
Mounted to my old cab, and I immediately found a difference, I can play with flat settings pluged into wtx260, and sound's better then my old muddy speakers. I think I will mount some ports to old cab to test response, before assembling final cab.
At begining I had plan do as a typical 212 cab but I found that site: DIY Loudspeaker Projects Troels Gravesen and was amazed how these speakers looks. I think guy know what he is doing, a lot of tips and advices can be found on his website. I tried contact him, but he replied that instrument speakers are not in his comfort zone.

For gigs I have david eden 212xlt, but that one I want to keep mostly in a house.
 
Sometimes cab design also includes design of art
We do tend to the utilitarian and the budget... The technology exists to have an alloy sheet laser cut to any grill pattern desired - at a price admittedly - and it would be kinda interesting to have something on the path less travelled... Trouble is I'm not an artist. I did have an idea for a mesh grill on an angle, but it looked an awful lot better in my head than it did when I drew it on screen so I'll spare you. Something like Escher's 'Two Birds' pattern might be interesting, or what else...
Backlight the grille or something... how about a mirror finish on the baffle behind the grille so the patterns could get thrown back by coloured spots?
AH, I don't know if you do show specials with Mesa, but a backlit grill with the Mesa logo as a grill pattern might attract a bit of attention, tho' whether it would match the company ethos is another matter...
 
We do tend to the utilitarian and the budget... The technology exists to have an alloy sheet laser cut to any grill pattern desired - at a price admittedly - and it would be kinda interesting to have something on the path less travelled... Trouble is I'm not an artist. I did have an idea for a mesh grill on an angle, but it looked an awful lot better in my head than it did when I drew it on screen so I'll spare you. Something like Escher's 'Two Birds' pattern might be interesting, or what else...
Backlight the grille or something... how about a mirror finish on the baffle behind the grille so the patterns could get thrown back by coloured spots?
AH, I don't know if you do show specials with Mesa, but a backlit grill with the Mesa logo as a grill pattern might attract a bit of attention, tho' whether it would match the company ethos is another matter...
I love idea with Escher patterns! Don't know how much it will cost
 
I love idea with Escher patterns! Don't know how much it will cost

Not cheap I suspect: you get to throw away a lot of aluminium.
Here's an idea. Based on "Two Birds" with a lot of detail removed. I think looking at it again the metal would need to be thicker and the holes smaller. I reckon that would be too fragile to be practical.

eschergrill3..jpg
 
I think looking at it again the metal would need to be thicker and the holes smaller. I reckon that would be too fragile to be practical.
Too fragile and also I think you may want to avoid pointy stuff like these details:

IMG_20190611_043129.jpg

Also, if you make your own design, make sure to check it has the minimum open area required (don't know the percentage for bass cabs, I only know for car speakers) :)
 
Also, if you make your own design, make sure to check it has the minimum open area required (don't know the percentage for bass cabs, I only know for car speakers) :)
Might be more an issue with car speakers cause these push lots of reactive acoustial power (moved air volume).

If any there could be (at most) an issue with the ports IF the grill was too close to the opening of the ports.

You may also read @fdeck's waveform based graphs to learn more about (none sinusoidal) signals in real world practice.
fdeck
 
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Easy surface mount grilles make cabinets look like cheap car audio or DJ gear imo.

Never mind my suggestions, build as you like.

Lol , couldn't agree more

People spend alot of money to have really really ugly cabinets.

Few more extra steps and time.
Cabinet can have much better appearance.

Often quoted as looking like cheap car subs. But even now cheap car subs actually put alot effort into simple grills that look much much nicer.

Know what you mean though. How many more TeARfull I mean ugly FeArFul threads do we have to see. Before people include better asthetic in build plans
 
Here in the US, we refer to that first option as 'bisquits'...technically they are a type of loose tenon. They work well and definitely strengthen a joint. If you already have experience using them and the specialized tool they require, then it's certainly not a bad option...if you don't, I wouldn't bother. Likewise, the rabbet-and-mortice you drew is also an exceptionally strong joint if well executed. But in my experience, plain old butt joints, glued and screwed (or nailed) are more than strong enough for a speaker cabinet.