Hey C-Chuck, thanks for the quick reply. I posted those pictures too fast this morning & didn't really mean that design. This is the one I am thinking about. http://arqen.com/wp-content/media/ac...al-588x315.jpg
Same dementions, no rounded tops! The problem is all those wells of different depths. This design should be a bit simpler. I was thinking I could use plywood & lumber for the basic design. That would be easy. I also thought the easiest plan would be 2x4's on top of the basic frame which I could router ahead of time.
I hadn't considered using my Circular Saw with a guide. The Milwaukee would be fast and certainly has the power for the job (15 amps). Faster than a router, I don't know. There would be many cuts with the circular saw...unless there is a special blade for that purpose (cutting grooves). If there is, that would be ideal. But that is why I came here. I felt you guys no just about everything about tools & woodworking. I think I remember in high school seeing a table saw with a dado blade that cut grooves. Does that sound right? Anyway, this is the basic plan for 1 of the 7 panels which when completed would hang side by side on a French cleat. I'm thinking I would make them 6 ft long. These are the instructions he sent me. I have the depths of each well on another email. I will look them up.
Everyone seems to love fractal diffusers, but to most of us they look ridiculously hard to build. I've tried to break it down for you with this modular fractal stepped diffuser.
I'd like to introduce you to my favorite diffuser design: the Leanfracal. You may have seen it featured on the Arqen.com homepage, or read about it in my diffuser design thesis (where it's known as A1-Frac).
Click "Display Images" to see me (señor Leanfractal).
The Leanfractal is my personal favorite because you can mount it using the same profiled modulations that are given for the Leanfuser. Mounted this way it can perform better than my other fractal diffuser design, the Stepfractal (B2-Frac).
The Leanfractal is also simpler to build! It's a straightforward extension to the Leanfuser. In fact, you can build an array of Leanfuser panels first, then upgrade them later to Leanfractal panels.
Here's how to build it:
Step 1: Build Leanfuser modules according to the A1-LF fabrication drawings I sent you earlier. If you can't find this document, see my older email titled "Here are the free DIY diffuser blueprints you requested".
Step 2: Build the small fractal cells. Details about them are given in the FAQ here. One way to make them is on a milling machine, like Schaap has done here and here. If all you have to work with is a Dremel, a 5/16 Dremel router goes just deep enough to cut the middle fractal groove in Schaap's version of the design. In this case you would also need a Dremel router table which is inexpensive.
Step 3: Mount the fractal cells onto the Leanfuser modules. You now have Leanfractal panels!
Click "Display Images" to see Leanfractal panel assemply
Step 4: Mount your Leanfractal panels using the same profiled modulations recommended for the Leanfuser (To learn how to mount 5 or 7 panels, see the last pages of the A1-LF fabrication drawings document). If you want to instead mount 3, 4 or 6 panels, see the FAQ.
Click "Display Images" to see Leanfractal array (Profiled Modulation 2)
And that's it!
FYI, I'm using the words 'modules' and 'panels' interchangeably. In earlier work I always called them modules but 'panels' is more intuitive to most of us.
Also, keep in mind that all diffusers will exhibit a small amount of absorption. In general, the rougher the surface, the more absorptive, so fractal diffusers tend to be more absorptive than their non-fractal siblings. Some absorption is inevitable but to minimize it, varnish the surface of your diffuser to make the material as reflective as possible.
I am open to all suggestions, but just like everybody, I'd like to consider the cheapest solution while maintaining quality.