ASSEMBLY OF A KLIPSCHORN FOLDED BASS HORN REPLICA
The photographs shown below were taken during the assembly of a Klipschorn folded bass horn replica.  The photos are not arranged in any particular order.  The project was undertaken to illustrate the complexity of the horns construction.  It is a significant challenge to build even for an experienced cabinet maker. 

The plans used to construct this unit were rumored to come from Rudy Bozak (d:1982) who received a set of drawings from Paul Klipsch (d:2002).  The build shown below deviates from the plans in three areas, the throat opening (was 6x13", is 3x13"), the thickness of the the two panels that comprise the woofer back chamber (was 1/2", is 3/4" Baltic birch multi-ply) and the front panel (was 1/2", is 3/4").  Regardless of the source of the plans, they do produce an accurate replica of the folded unit manufactured by the factory today.  Note that in the build shown below, the panel opposite the woofer access opening is stiffened by two "tabs" created by the three 90° notches cut into the rail.  The tabs, when glued to the panel surface, provide considerable resistance to spurious resonance.  This design element, detailed in the plans used here, is not found in either the original plans or the current factory build*.

*A photo of a factory build is shown at the bottom of the page.
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KLIPSCHORN FACTORY BUILD
Photo of a Klipschorn work-in-progress at the Hope, AR facility (circa 2000).  Compare to the photos above (photo courtesy Klipsch, LLC).

Factory_1


Note additional aft braces along tail-board panel shown in vintage unit, lower left.  Design is similar to the original embodiment of Klipschorn first produced by Klipsch (lower right).  In drawing, note "splitter" attached to tail-board. 

early_Klipschorn P02_original