Follow the steps to assemble the speaker:

Download the CAD file and print it on a 3D-printer. The speaker should be printed in two parts divided on the middle of the slender side. Make sure that each part is printed on the speaker. This will result in a lot of support structure on the bottom of the print but it will alsoprevent the joint line from warping.

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In the middle of the print you see the joint line, and the top and the bottom of the speaker you see the support structure.

Remove the support structure. This is a tricky process so have a bit of patience. Use a pliers and a hobby knife to seperate the support structure from the speaker.

Abrade the two parts with sandpaper. Look out for pointy corners or rough unev areas, especially where the support structure has beem removed, and try to even the out.

Glue the two parts together. Place the of the table and try to fit them together. Look if it fits completely. If not you can use a file to to remove a bit of the material where it is needed in order to make it fits perfectly. Use “Loxeal instant 14” to join them and let it dry for 10 minutes.20170403_131456.jpg

Spartle the model with “Finspartel”(smoothing trowel) from Danalim.

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Smoothing trowel from Dana Lim
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Make sure that your spartle the joint of the model from both inside and outside.
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Cover the entire outer surface with a thin layer of smoothing trowel.
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When the spartle is dry abrade the model with sandpaper for a nice surface

You might want to do this step more than one time  for a smoother surface finish.

Pre-treat your 3D printed model with a primer. It is better to treat it with several thinner layers than one thick layer.20170331_182906.jpg

Collect a handle bar. The diameter must be around 20mm but make sure to measure to measure the exect diamiter on your printed 3D model since this can differ effected by the print quality the printer. If its not a perfect fit you can always grind it down a bit.

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Insert the handle bar in 3D printed part and mark with a pen where the surface of the speaker stops

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Cut off the ends of the handle bar.
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Abrade the ends
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Insert the handle
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Even out the handle bar and the surface with sandpaper to make a smooth transition between the handle and the surface of model.
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This is the result you’re aiming for. It might be a good idea to prime the model again since the primer has been removed during the abrasion.

Painting the model. 

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Paint the printed model in a desired colour. We have chosen the colour “indigo” – a deep blue colour. Remember to paint all the surfaces at least 3 times, or until the primer is completely covered.

Lasercut the mounting plate

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Download the file “mounting_plate” and lasercut it on a 3 mm plate.
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Paint the mounting plate a colour of your choice. Remember to start with a primer for a better result.

Collect or cut two blocks and a couple of magnets. 

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Glue the magnets on the edges of the mounting plate

Mount the raspberry pi

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The raspberry pi has been mounted on a plate in the bottom.

Inserting the speakers

It is a good idea to start with testing the sound before mounting the speakers.

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Glue the bolts for the big speaker on the backside of the mounting plate.
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Mount the small speaker on the mounting plate. Connect it to the raspberry pi and drag the rest of the wires out through the hole for the big speaker.

Now connect the wires to the big speaker before mounting it on the mounting plate. Mount the speaker by fastening the nuts.

Lasercutting the front plate

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Find your favourite pattern and lasercut the front plate

Glue magnets on the front plates and make them fit to the magnets on the mounting plate. Mount it to finish the MGA Speaker.

Put on the front plate and you are done.

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