KV2 Refurb Project 2021 Part 1
Short timelapse of the disassembly of the ES1.8
The first part of the rebuild project was to strip all the speaker cabinets down to the bare carcasses. We started with the four ES 1.8 subs as seen in this timelapse. The eight handles were removed, followed by the grill, and then the driver. For each of the screws on the outside of the box, careful cleaning of the screw heads was required. A compressor was used to help blow out the dirt from the screws.
What can’t be seen in the film is removing the connector plate from inside and also the locating pucks on the outside, which also needed their hex screw heads cleaning out.
WEEK ONE: Strip and clean ES 1.8 subwoofer cabinets
STEP ONE: Removing steel handles
Each sub has eight handles secured by wood screws into the cabinet. Over the years, the screws have become very rusty and all of the screw heads were full of dirt, meaning that a screw driver bit wouldn’t fit into them securely, so the screws couldn’t be removed without rounding the heads out. Each screw head had to be cleaned out with a tool which we made, before it could be taken out. As there are twelve screws in each handle and eight handles per sub and a total of six subs to strip, that’s five hundred and seventy six screws to clean in the subs alone, before we can even start taking the boxes apart. On removing the handles, the silicon used to seal them to the boxes needed to be removed with a stanley blade.
One important thing to do when re-building a system like this, especially when it is comprised of several different types of speakers, is to keep all the different screws and fittings separate and labelled properly. Sometimes, the fixings look very similar, but just won’t fit in the wrong hole, so organisation is important when it comes to being able to re-assemble the system correctly.
STEP TWO: Grill Removal
The same steps were taken to clean the screw heads out on the grills. The grills are steel and the paint is almost non existent, so they are in a poor state. On a couple of the boxes, the grill material is actually cracked. It may be difficult to get hold of new grills as the design of the grill has changed since this original variant. As we have fabrication facilities on site, we will tig weld the cracked metalwork back together, followed by cleaning all rust and paint off with a wire wheel cup for an angle grinder. When all speaker grills from all ten boxes are straightened out and cleaned up, they will be sprayed together.
Removing the 18″ driver from each box required taking out the eight bolts and disconnecting the wire terminals from the driver’s chassis. After that, the connector plate could be removed from the inside of the box.
STEP THREE: Cleaning
Having stripped the speakers down to the bare boxes, it was clear that the seventeen years of beer, dirt and chewing gum, wasn’t going to come off easily by hand. The pressure washer did an admirable job of getting the speakers clean, ready for prepping for paint.