Ok, here's the system.
To save time, money and effort on my part, I just did a variation on a kit available a Zalytron in NYC.
http://www.zalytron.com/
It's basically the German 2-Way kit (Budget section) multiplied by 4 and laid out as a line array. These are the same drivers used in the previous version of the Alesis M1.
Why his design?
Most
pro speakers use horn loaded compression drivers coupled with large midbass drivers to achieve high SPL's (Sound Pressure Levels) and control directionality. This system works on a different principle. It achieves a narrow vertical directionality (desirable) by putting multiple drivers in a line. Interference cancels sound in the vertical direction rather than squeezing it down with a horn. Since the drivers are relatively small wide horizontal dispersion is maintained (desirable). Multiple drivers and the extra surface area and power handling they provide allows the use of relatively low efficiency hi-fi components (4x7" drivers are about equivalent to 1x12").
Details
Boxes
Rough drawings are attached. They include all of the critical dimensions. The second speaker should be built as a mirror image. Joinery details are left up to you. I drew butt joints, but dados and rabbets are preferred. You can get the driver cutout diameters from the Axon datasheets posted at Zalytron. The tweeter holes are routed rather than cut through. Flush mounting the tweeters in nice but not critical in this case. Small holes will need to be drilled behind the tweeters and between the internal walls to run the wires. They should be caulked afterwards. The chambers should be stuffed with 0.5 lbs/sqft Acoustostuff filling. Terminals are left up to you.
Do not use speaker grills of any kind and do not extend the box sides out beyond the front. The side corners should be rounded. The speakers can be attached face to face with some sort of spacer to protect the drivers during transport. The top and bottom panels of the box can be extended beyond the front to help facilitate this since the line arrays don't radiate vertically at higher frequencies.
Box covering, handles, mounting fixtures are left up to you. Don't put carpet or anything soft on the front. A good source for this stuff is Parts Express
http://www.partsexpress.com/
Crossovers
The drivers are wired such that they present to same load to the crossover network as a single driver. The German 2-Way crossover schematic, therefore, is basically unchanged. The only thing I have done is specify higher quantity components and replaced the single resistor with 4 resistors in order to account for the higher power handling capabilities of this system.
Zalytron has a special on the Axon drivers: 10 woofers for $180 and 10 tweeters for $150. Call Elliot there and tell him you are doing this variation on the German 2-Way. You need 8 of each driver, the crossover circuit board, and the upgraded crossover components. It's cheaper to buy 10 drivers than 8, but maybe he can cut you a deal where he keeps the extra drivers in exchange for the circuit board, upgraded crossover parts and maybe some other parts?
Usage
These speakers are fairly specialized for the guitar and vocal range. Not that they can't be used for any music, but they do have a couple "problems".
1. Not a lot of bass extension. The -3dB frequency is about 80Hz. The closed box gives it a shallow -12dB/octave rolloff so they still give good response at 70Hz if you tune down to D.
2. High frequency vertical comb filtering. The separation between the tweeters will cause significant response peaks and dips above 10kHz as you move up or down from the vertical axis. Guitars and vocals don't have a lot of information in the region so it shouldn't be a problem. Even with broader band music it's not overly bothersome, and compression horns also have response problems of their own above 10kHz.
The efficiency of these speakers will be about 95dB/W/m. This is on the low side for sound reinforcement, but they will easily fill up a coffee house or small club. A 100W to 200W amp should work well.
I can give more details if anyone decides to built it.
barefoot