Making The First XL Horn Speaker

This was a test run for Andrew Bird to see how a horn this large would work on a large stage.

After the initial process of establishing a shape for the speaker horn, the next logical step was to enlarge it by 400%!

This resulted in a rather unwieldy construction going together but once the last seam was closed, I added reinforcement layers and the final shape was amazingly rigid.

A quick finish was applied and it was ready for Andrew Bird’s Millennium Park Labor Day show in 2008.

The results were amazing. I was in the audience about 200 feet back from the stage and the sound projection was stunning. After the show Andrew ordered a pair and I had a mold made of the prototype. The original prototype was shredded to bits coming out of the mold, but the mold lives on an we are able to produce these magnificent horns for special applications.