Wedge stage monitors are a good do-it-yourself project for anyone who deals with PA systems for live performances. A wedge-shaped monitor is one of the best types to use for sound projection on a stage. Basic carpentry skills and a soldering gun can provide these special monitors.
Measure the speaker's width and depth with a measuring tape, then add two inches to these measurements. Mark the outlines for the two side sections of each monitor on a sheet of plywood, using the measuring tape and marking pencil. Measure so that the back of each side section is 1.5 times longer than the front section and so that the bottom measurement of each side section is equal to the back of the section (allowing for the depth and width of the speaker measurements plus the two extra inches).
Using the measuring square, draw a 45-degree angled line, starting at the top of the back line and ending at the top of the front line of the side section. Cut the side sections out along these lines with the table saw or circular saw.
Draw rectangles on the plywood--for the front and back sections--to match the dimensions of these segments of the side sections. Make them equal to the width of the speaker, plus four inches. Cut out the front and back sections with a saw.
Cut out a section of plywood that is equal to the measurements of the back section, plus one inch in length and width, for the front speaker-mounting section (known as the baffle). Cut out another section of plywood, with the exact measurements of the baffle, for the bottom section.
Lay the baffle section flat and place the speaker in its centre. Draw an outline around the speaker on the plywood and mark the mounting bolt holes (found in the speaker rim) on the plywood. Remove the speaker from the baffle.
Measure the distance between a mounting bolt mark and the outline. Use a compass to draw another line in the centre of the speaker outline so that the second line is the same distance from the mounting bolt holes as the measurement between the mounting bolt holes and the outline.
Use a jigsaw to cut a hole along the inner line. Drill the mounting bolt holes, using a ¼-inch drill bit. Smooth down all the saw-cut edges with the medium-grit sandpaper.
Glue the side sections to the outside edges of the bottom section, using wood epoxy. Glue the front and back sections to the edges of the stage monitor.
Attach the speaker to the baffle with bolts and T-nuts.
Use the wire cutters to cut a piece of speaker wire long enough to reach from the terminals of the speaker to one side section (plus two inches) . Using the wire cutters, separate the leads of the ends of the piece of speaker wire to a distance of one inch.
Use the wire strippers to strip one inch of the insulating wrap from each end of the piece of speaker wire. Secure the leads of one end of the piece of speaker wire to the terminals of the speaker, using the soldering gun and resin-core solder.
Drill a ¼-inch hole in a side section of the stage monitor. Place the speaker jack plug in the hole and tighten it down with pliers.
Attach the leads of the other end of the piece of speaker wire to the jack plug. Glue the baffle to the top of the stage monitor with wood epoxy.
Use the drill and screwdriver bit to install wood screws into the joints of every section. Smooth down the entire stage monitor, except for the baffle, with fine-grit sandpaper.
Your wedge stage monitor is complete.