So, continuing from my earlier post:
I'm getting a used Rumble 210. I've been looking at various options and thought that a metal grille would look good.
So a few questions to those who did it and to those who are considering it:
1. How much open area do you think is a reasonable minimum?
2. Would you do it in perforated sheet or in metal weave?
3. What thickness do you think is minimum? Is 1 mm good or will it be too flexible?
4. What material would you recommend? My options include galvanized aluminum (black), untreated aluminum (silver), steel, brass or copper.
5. It's going to need a new frame since the original one is already a tight fit with the cloth grille. What frame material would you use for this? Wood or something else?
The easiest way is to buy the standard grille cloth. I could make two separate frames: one with fabric oriented horizontally, the other vertically, so it looks right with the cab standalone and when stacked.
BUT THERE'S NO FUN IN THAT!
I researched the available options for perforated metal and meshes. EU standards for perforated metal sheets mean that:
1. Highest open area (~80%) is available with honeycomb perforation (Hv 4.5-5 or Hv 6-6.7). The best square perforation is around 70% (Qg 10-12). The best round perforation (oriented at vertices of an equilateral triangle) is around 63% (Rv 5-6 or Rv 15-18).
Acoustically transparent speaker cloth gives much higher effective (acoustic) open area, and cab manufacturers simply accept that, when using metal grilles, some (potentially a lot) of acoustic energy will be lost to absorption and reflection, but it's apparently not that much since it's a fairly popular option.
Mesh scale is also standardized. Mesh 6 (pitch=1⁄6") with 0.5 mm wire is ca. 78% open area. Mesh 10 (pitch=1⁄10") with 0.4 mm wire is ca. 71% open area, sieve size 1.6 (1.6 mm pitch) with 0.4 mm wire is 64% open area.
3 (and 5). 1 mm thickness is perfectly fine, since it will be affixed to a wood frame.
4. About the materials. Not all metal or mesh options are available in all materials, but it's more down to color than anything else.
So I drew up mock-ups of the various options and I need your input. All are modeled on the Rumble 115, picture courtesy of Thomann. First are all the options (hexagonal Hv4.5-5 and Hv6-6.7, round Rv5-6 and Rv15-18, square Qg10-12, sieve size 1.6 in copper and brass and mesh 6 in copper and brass, then close-ups of each of the options.
Up close: