Zaph Audio ZRT 2.5 Way Kit User manual

Zaph Audio ZRT 2.5 Way Kit Instructions
1. Take your time, and think about every step before taking action. It is a good idea
to clear your workspace of all non kit related parts, and lay everything out prior to
beginning. These directions reflect the way we assemble this kit when using the
MD38T cabinets and pre-cut baffles. You may have your own techniques that suit
your style or experience. Go with what you are most comfortable with.
2. Remove front baffle from cabinet with a Phillips head screwdriver. Keep the
screws and washers close by, you will need these again. You will not need this
baffle again.
3. Remove the solid brace by sliding out towards you. Remaining will be two more
braces in the cabinet that are not solid. Either discard the solid brace, or make a
series of cuts to allow free air flow like the two other braces.
4. *** See crossover hook up sheet *** Cut wires to proper length. You should use
~ 12” x 2 for input cup to crossover, ~ 30” for the lower woofer, ~ 40” for the top
woofer, and ~ 50” for the tweeter. Strip ends 3/8”, tin the stripped ends and solder
to the crossover boards as indicated in the hook up sheet. Observe polarity. Mark
the ends of both the input and output set of tweeter and woofer(x2) wires with a
marker or tape for easy identification later.
5. With all wires now attached to the crossovers, remove double sided tape strip
from the bottom of the crossover board and press the woofer crossover firmly to
the bottom of cabinet. Place the tweeter crossover on the rear wall above the input
cup cut out. For best results, get this right the first time. We have also included
some 6PAN3/4” screws that you may use to further solidify the crossover
mounting. Make certain to mount the crossover board so that the input wires are
close to the back side of the cabinet. This will allow easier access to the input cup
cutout in the cabinet.
6. From the back side of the cabinet, pull the wires through the input cup cutout.
Solder the wires to the input cup, low pass input wires to the bottom set of
binding posts and high pass (tweeter) input wires to the top set of binding posts.
Mount input cup into cabinet with the provided OX Oval 6x34”screws. Leave the
gold jumpers connecting the top and bottom sets of binding posts in place, unless
of course you bi-wire or bi-amp these speakers.
7. Cut the provided foam sheet into appropriate sized pieces to line the back and side
walls. Apply Goop to cabinet walls and the cut foam sheets, wait a minute, and
press onto appropriate walls. It is not essential to cover every square inch of the
internal cabinet walls. A double layer may be used on the rear wall.
8. Take provided Acousta-Stuf and split in half, one half for each speaker cabinet.
Fluff up by pulling apart in all directions, and do this multiple times. Fill the
entire cabinet with the Acousta-Stuf. Do not pack it into the cabinet, just fill it and
press it in lightly. You do not need to use all of the provided Acousta-Stuf.
9. Apply foam gasket tape to the internal perimeter of the cabinet, where the front
baffle will eventually rest. The purpose of this step is to ensure an airtight seal
between the baffle and cabinet. Some customers prefer to use their own alternate
sealer product, removable or permanent.

10. Properly mount the MD38-B2 pre-cut baffle into the cabinet with the screws and
washers from step 2. The tweeter hole should be on the opposite end as the
already installed input cup. Do not over tighten the screws when mounting the
baffle. Rather give them a turn every day or so until the gasket has fully
compressed. The baffle is now correctly installed.
11. Pull the remaining wires through the appropriate cutout holes in the baffle. You
have marked the wires with a marker or tape in step 4. At this point, take a look at
how the internal wire has arranged itself inside the cabinet. A small amount of left
over Acousta-Stuf or some that is accessible in the cabinet may be used to ensure
the wire will not rest, rub or tap against any hard surfaces or other drivers in the
cabinet.
12. Carefully solder the leads to each driver. Observe polarity. (If you are questioning
your soldering skills, we have provided quick connects to make this step a little
easier. Once you crimp the quick connects on the stripped ends of the wire, press
them onto the appropriate tabs of each driver. We highly recommend that you
make this connection permanent by soldering the quick connects to the driver tabs
at this time.)
13. Take note of how you want the screw alignment to look when the drivers are
mounted in the cabinet. Line up the drivers according to your preference in the
baffle recess and drill pilot holes with a small drill bit. Mount the drivers into the
cabinets with the provided screws. We have provided you with your choice of
Phillips head or Socket head screws. Note: Bring the screw head just short of
contact with the driver flange, and then tighten each screw slowly allowing the
gasket to compress and the driver to become flush with the baffle.
14. Your ZRT 2.5 Way kit is now complete.
15. Plug, play and enjoy!
Detailed information on this kit is available at www.madisound.com and
www.zaphaudio.com