Omar Khalid
A speaker cone can get damaged in several ways, from accidental dropping to a drill piercing the cone. While some speaker cones can be repaired, others may need to be replaced. This is a guide on how to replace a plastic speaker cone.
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What You'll Learn
Using glue to repair a plastic speaker cone
Repairing a plastic speaker cone with glue requires careful application and the right type of glue. The first step is to select a suitable adhesive. Some common types of glue used for speaker cone repair include flexible adhesives, such as rubber-based adhesives, silicone gel, polyurethane adhesive, and fabric glue. It is important to avoid using hard glues like cyanoacrylates (superglue), as they can cause cracking.
Once you have chosen the appropriate glue, it's important to dilute it slightly with water to ensure it soaks properly into the speaker cone. The recommended ratio is one part water to three parts glue. Apply this diluted glue to both the inside and outside of the tear, allowing it to dry. For very small tears, you can use a small brush to "comb" the fibres towards the tear, helping them join in the middle as they dry.
After the glue has dried, cut a patch from a coffee filter or tissue paper, ensuring it covers the glued area and extends slightly beyond it. Tear the paper instead of cutting it to create a feathered edge that bonds better with the cone. Apply a liberal amount of glue to the top and bottom of the patch and secure it over the tear.
For extra strength, consider patching the back of the cone as well. It's a good practice to let the patch dry between applications if you're using multiple layers. While repairing a plastic speaker cone with glue can be a straightforward process, it's important to be cautious and patient to achieve the best results.
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Reinforcing the repair with tape
While there are a few methods to repair a cracked speaker cone, reinforcing the repair with tape is a common method. This method can be used for both paper and plastic cones.
First, you need to fill in the crack with glue and let it dry. Depending on the severity of the crack, you may need to apply several layers of glue to both the top and bottom of the cone. You can use glues such as Elmer's glue, gorilla glue, or another semi-flexible wood glue.
Once the glue is dry, you can reinforce the repair with tape. One option is to use sewing tape, which provides structural strength and rigidity to the repair. You can apply the tape to the back of the cone, along with a suitable glue, such as contact adhesive. This method is especially useful for plastic cones, as the tape adds structural support.
Another method is to use blue painter's tape, which has a negligible effect on the mass of the cone. You can also experiment with adding additional pieces of tape or stiffening ribs radially around the cone to reduce distortion.
If you are looking for a stronger bond, you can consider using duct tape or duck tape. However, these options may be heavier and could potentially affect the sound by dampening the movement of the cone.
It is important to note that these repairs may not make your speakers sound better than they did before they were damaged. However, the goal is to improve the sound quality compared to when the cone was cracked or damaged.
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Using a vacuum to reshape the cone
To reshape a warped or damaged speaker cone using a vacuum method, you'll need a few supplies and some patience. Here's a step-by-step guide:
First, you'll need a vacuum pump, which can be rented or purchased. The pump should have a gauge to monitor the pressure, and you'll also require a vacuum bag or chamber that can accommodate the size of your speaker cone. Place the speaker cone inside the vacuum bag or chamber, ensuring it is centered and not folded or creased. Seal the bag or chamber securely, leaving a small opening for the vacuum hose. Attach the vacuum hose to the pump and to the opening on the bag or chamber. Turn on the pump and begin to create a vacuum. Monitor the pressure gauge and maintain a steady, gentle vacuum. Do not overdo it, as you could risk damaging the cone further.
As the air is removed, the speaker cone should begin to reshape. This process may take some time, depending on the severity of the warping and the material of the cone. Check the cone's progress periodically, but try not to disturb the vacuum seal unless necessary. Once the cone appears to have taken a suitable shape, release the vacuum slowly and carefully. Do not rush this step, as sudden exposure to atmospheric pressure could cause the cone to distort again. After releasing the vacuum, inspect the cone for any signs of damage or remaining warping. If necessary, repeat the process, but be cautious not to overdo it, as multiple attempts could weaken the cone material.
This method is a delicate procedure and may not always yield perfect results, especially with severely damaged cones. The success also depends on the material of the cone and the skill of the person performing the repair. It is always recommended to handle speaker cones with care and, if possible, seek professional help for repairs to avoid further damage.
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Repairing the outer rubber suspension
First, it is important to assess the condition of the speaker and identify the issue. In this case, we are focusing on repairing a tear or hole in the outer rubber suspension, also known as the surround. This part of the speaker is crucial as it is part of the suspension system, and a tear can lead to premature wear and further tearing if left unrepaired.
Next, gather the required materials. You will need a suitable adhesive, such as butyl glue, which is specifically designed for repairing rubber surfaces and will not stiffen over time like acetate or urethane glues. You can also use urethanes, acetates, silicones, latexes, or other butyl-based materials, but be cautious as some of these may harden over time. Additionally, you will need a small paintbrush or a toothpick for applying the glue, and a piece of tape or a small patch of material such as nylon, paper tissue, vinyl rubber, or cloth to cover the tear.
Before beginning the repair, clean the tear on both sides to ensure that the adhesive will bond properly. If using butyl glue, gently apply a small amount of glue to the split edges of the tear with a toothpick, rubbing it in until the edges soften. Allow the glue to dry for a few minutes, then apply a second coat. This process will cause the edges of the tear to "melt" together, forming a strong bond.
If using other types of adhesives, water down the glue with a ratio of one part water to three parts glue. Fill the crack with the glue mixture and let it dry. Depending on the severity of the tear, you may need to apply several coats. Once the glue is dry, cut a piece of a coffee filter or your chosen patch material to size, covering the glued area by about a quarter to half an inch on all sides. Use your paintbrush to apply glue to the top and bottom of the patch and the speaker cone itself, then carefully place the patch over the repaired area.
Finally, allow the glue to dry completely before testing the speaker. Be aware that the repair may not restore the speaker to its original condition, and the sound quality may still be impacted. Additionally, keep in mind that playing the speaker at high volumes may cause further tearing, so it is recommended to monitor the speaker's performance and adjust the volume accordingly.
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When to replace the speaker cone
A speaker cone can be replaced or repaired for a variety of reasons, depending on the type of speaker and the extent of the damage.
If a speaker cone has a puncture, tear, or crack, there are several methods to repair it. The type of glue used to repair a speaker cone can vary, with some recommending rubber cement, wood glue, or RTV silicone. The glue can be applied directly to the cone or used in conjunction with a patch, such as tissue paper, a coffee filter, or a piece of cloth. In some cases, a combination of glue and a patch may be necessary for a more durable repair. It is important to note that the repair method may depend on the type of speaker and the severity of the damage. For example, a guitar speaker may be patched without significantly altering the sound, while a hi-fi speaker may require more precision to avoid impacting the tone.
In other cases, a speaker cone may need to be replaced due to mechanical or thermal failure. Mechanical failure can occur when the cone moves beyond its limits due to excessive power or low frequencies, resulting in damage. Thermal failure, on the other hand, can be caused by issues such as freak feedback, clipping amplifiers, or poor AC power. If the speaker is completely dead, replacing or reconing it may be the only options. Reconing involves replacing all the moving parts, including the cone, voice coil, and surround.
Before deciding to replace the speaker cone, it is essential to examine the other components, such as the crossover, jacks, speaker cable, and internal wires, as the issue may lie elsewhere. Testing cables with known working cabinets and checking for broken solder or loose connections can help identify the root cause of the problem. Additionally, checking for warranty coverage and consulting customer support can provide guidance on the next steps and potential repair options.
Ultimately, the decision to replace or repair a speaker cone depends on the nature of the damage, the type of speaker, and the availability of replacement parts or repair kits. In some cases, replacing the entire speaker may be more cost-effective, especially if the repair process is delicate and requires expertise.
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Frequently asked questions
You can repair a plastic speaker cone with glue. Water down the glue so it will properly soak into the speaker cone. Mix the glue with one part water to three parts glue. Fill in the crack with glue and let it dry. Cut a piece of a coffee filter to size so that it covers about a quarter to half an inch on every side of the crack. Use a paintbrush to glue the patch on. You can also use tape to hold the split together.
You can use various types of glue to repair a plastic speaker cone, including:
- Semi-flexible wood glue, such as Elmer's glue
- Epoxy
- Fiberglass resin
- UVA glue
- Superglue
- Rubber cement
- 3M weatherstripping adhesive
You can try the following methods to unpop a plastic speaker cone:
- Stick a piece of tape to the centre of the speaker cone and slowly pull the tape out
- Place a cardboard tube around the cone and breathe in forcefully through the other end
- Use a vacuum cleaner on a low suction setting and place it over the speaker cone
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