Ron's 2016 Cabinet Work Part I: Bozak E-300

Ron's 2016 Cabinet Work Part I: Bozak E-300 - Printable Version

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Ron's 2016 Cabinet Work Part I: Bozak E-300 - Ron Ramirez - 06-30-2016

Well, I'm going to try to redo a few cabinets this year.

Top priority is a set of two 1950s Bozak E-300 (B-300) speaker cabinets. I've had these for two or three years and The Boss (Debbie) said I need to get them fixed up and out of the basement. Icon_eek

The following illustration will give you an idea of what they look like:

[Image: http://www.philcoradio.com/images/phorum/bozak_base.jpg]

The red arrow is pointing to the base (riser), which I am going to have to replicate on both of mine. The original risers were removed and casters installed at some time. I'll also have to replace the upper and lower trim, and replace the grille cloth.

New grille cloth is on the way, as is a lighter color grain filler as these cabinets are lighter than the typical walnut radio cabinets.

I'll try to take some photos this weekend before I begin the process of removing the speakers and tearing each cabinet down. I hope to get both torn down and the tops stripped this weekend. Hopefully by the following weekend, the grain filler will be here and then I can start the process of refinishing the tops of both.

Oh, don't let that "Little Giant" name fool you. These cabinets are huge...and heavy! Each cabinet holds a single 12 inch woofer, with not one, but two tweeters mounted coaxially.

I've decided that I can go ahead and redo the main body of each cabinet, and build new risers later. I am hoping I can find the right size wood to make the risers. Otherwise, I'll have to invest in a table saw to make the necessary precision cuts...$$$...

RE: 2016 Cabinet Work: Bozak E-300 - Eliot Ness - 06-30-2016

Interesting speakers, I'm looking forward to some pictures as you progress.

RE: 2016 Cabinet Work: Bozak E-300 - Paul Philco322 - 06-30-2016

I have had good luck with asking folks around town or that I know in the trades to make cuts, borrow tools, etc..
It can save bucks and many are glad to help on a non professional basis.

Good luck.

Paul

RE: 2016 Cabinet Work: Bozak E-300 - Ron Ramirez - 06-30-2016

John - Thanks, will definitely post pictures as I go along.

Paul - Unfortunately I don't know anyone locally who can do that stuff Icon_sad

RE: 2016 Cabinet Work: Bozak E-300 - GarySP - 07-02-2016

Finally, Ron! A chance to feel like I can make a contribution to the Phorum cause. What I lack in electronic skills I make up with woodworking skills. PM me with the outside dimensions ( length, width, height ) of the risers you need for your speakers, and I'll build you a set. I'll need a shipping address as well. Consider it a little house-warming gift on my part. The photo leads me to believe that they were just flat black. Let me know how you want them finished as well. Take care, Gary.

RE: 2016 Cabinet Work: Bozak E-300 - Ron Ramirez - 07-02-2016

Gary - Bless you! Icon_e_surprised

I don't deserve friends like you...really I don't...

PM forthcoming.

RE: 2016 Cabinet Work: Bozak E-300 - Ron Ramirez - 07-02-2016

Here are the candidates:

[Image: http://www.philcoradio.com/images/phorum/bozak_001.jpg]

I don't think the grille cloth is original; I've never seen any cloth that looks like this on any of the Bozak E-300 photos I have seen.

The cabinets are pretty rough. They are getting close to 60 years old, and they show it. Here's a close-up of the top trim on one of them:

[Image: http://www.philcoradio.com/images/phorum/bozak_002.jpg]

The bottom trim had been replaced by some cheap home interior trim some time ago, and the risers were removed and casters added. I suspect these boxes were put on casters due to their weight; casters would make them easier to move around but it removes the originality.

I had planned on replacing top and bottom trim as part of this project. The top trim has to come off in order to get the old cloth off and to install the new cloth.

I noticed something else I had previously overlooked:

[Image: http://www.philcoradio.com/images/phorum/bozak_003.jpg]

Yes, one of the Bozak nameplates is broken. Icon_cry

I will attempt to glue it back together with J-B Weld later.

RE: 2016 Cabinet Work: Bozak E-300 - Ron Ramirez - 07-02-2016

Upon opening one of the cabinets, I found a surprise waiting inside...a most excellent surprise:

[Image: http://www.philcoradio.com/images/phorum/bozak_004.jpg]

Yes - a B-209 midrange speaker and a Bozak 3-way crossover network! Icon_biggrin

So these are B-302A speakers, not B-300s. That is a great thing.

I had read on AudioKarma that the Bozak nameplates are just pressed into place. Whoever posted that information was exactly right - carefully, using a putty knife, I was able to easily remove both Bozak nameplates from the front of each speaker without damaging either one. Icon_thumbup

The backs of both speakers have been modified, more than once. Both have extra phone jack speaker terminals, with holes cut into the backs to accommodate them. Plus the backs have a couple more extra holes in them as well. Yes, I could just cut new plywood backs, but then they would not have "MODEL E-300" stamped on the backs anymore.

I'll figure out some way to repair the originals or, at least, to seal off the holes. The backs won't be visible in normal use so they do not have to look the best.

RE: 2016 Cabinet Work: Bozak E-300 - Ron Ramirez - 07-02-2016

I removed woofer/tweeter combos, midrange speakers, and crossover networks from both cabinets.

Looking underneath one of the cabinets in preparation to remove the casters, I made an interesting discovery:

[Image: http://www.philcoradio.com/images/phorum/bozak_005.jpg]

An outline of the original riser!

I will use the outer measurements of this outline to determine the outer dimensions of the original risers.

I also know from looking at this that the riser must have been flat black, as the paint under this cabinet is flat black.

RE: 2016 Cabinet Work: Bozak E-300 - Ron Ramirez - 07-02-2016

I began an attempt to remove the top trim from one of the cabinets.

I discovered that these trim pieces were not nailed on - they were glued on. Icon_eek

I was able to get one top side piece off...

[Image: http://www.philcoradio.com/images/phorum/bozak_006.jpg]

Unfortunately, my attempt to get the trim off the other side did not go so well.

[Image: http://www.philcoradio.com/images/phorum/bozak_007.jpg]

[Image: http://www.philcoradio.com/images/phorum/bozak_008.jpg]

Now I am in a dilemma. How do I get these trim pieces off without damaging the top of the cabinets?

RE: 2016 Cabinet Work: Bozak E-300 - GarySP - 07-02-2016

Hi Ron,
Try carefully sliding a lock blade knife between the molding and the cabinet itself. With a little effort it should separate. Take care, Gary.

RE: 2016 Cabinet Work: Bozak E-300 - Ron Ramirez - 07-04-2016

I tried using a lock blade knife at the joint between the molding and the top. But after the top started to splinter at the joint, I quit...

Then guess what I found.

The tops are removable!

[Image: http://www.philcoradio.com/images/phorum/bozak_009.jpg]

[Image: http://www.philcoradio.com/images/phorum/bozak_010.jpg]

In the case of the cabinet I was trying to remove the top molding from, I had to remove the paper insulation from the underside of the top in order to get to the attaching screws. Then it was a matter of removing the screws...and the top simply lifted off.

Well, it looks like I'll be investing in a table saw after all, as I have decided to construct new tops for these cabinets using 3/4" furniture grade plywood.

The molding is 1/4" x 1-1/4" and that should not be difficult to find. I found it on Home Depot's website, in that very size, listed as "lattice molding".

Now I know how Bozak was able to finish the tops and upper molding without damaging the grile cloth. The molding was glued onto the top, then the assembly was finished. I shall repeat that process...assuming my clamps are long enough...if not, I may have to invest in two or three more...

RE: 2016 Cabinet Work: Bozak E-300 - Ron Ramirez - 07-04-2016

I removed what seemed to be a million staples from the top and bottom edges of the grille cloth.

Afterwards, the cloth simply fell off and I was left with this:

[Image: http://www.philcoradio.com/images/phorum/bozak_011.jpg]

When I was finished, I repeated the process on the other cabinet.

It looks like there are several more staple holes other than the ones left by the staples I removed, so I am now sure the cloth I pulled from these cabinets was not original.

I plan to go over the front and sides with a touch-up coat of flat black paint before I begin to install the new cloth.

In case you're interested, the new cloth I selected is made by Mellotone and is beige and brown in color, patterned after a vintage Fender cloth. I bought mine from Parts Express.

http://www.parts-express.com/speaker-grill-cloth-fabric-beige-brown-yard-36-wide--261-810

RE: 2016 Cabinet Work: Bozak E-300 - Ron Ramirez - 07-04-2016

Since I'm going all out on these cabinets, I've also decided to go ahead and build new backs for each one.

If you are wondering why, let's look at the original backs:

[Image: http://www.philcoradio.com/images/phorum/bozak_012.jpg]

[Image: http://www.philcoradio.com/images/phorum/bozak_013.jpg]

All of the extra holes that have been put into these backs really detracts from their appearance. While I know that no one will see the backs when the cabinets are finished and in my home office, I would prefer that they have no holes so that the cabinets can be sealed as they were intended to be.

I can use a lesser grade of plywood for the backs, at least. I will have to fill in the original holes used to fasten the backs to the cabinets, as they have become well worn over the past several decades and use multiple sizes and types of screws to hold the backs in place. I want to use one single type of screw as was done originally.

RE: 2016 Cabinet Work: Bozak E-300 - KCMike - 07-04-2016

This is turning into an interesting project Ron. Look forward to seeing how it comes out.