Side Panel Grill - Bose 601 Series II

This is a replacement panel grill mount for my Bose 601 Series II Direct Reflecting Speaker. One of my speaker's original grill mounts broke cosmetically and so I modeled and 3D printed my own rather than shelling out $80 for a "new" one on an auction site.

In high school I 'rescued' a pair of Bose 601 Series II's from the garbage heap for the trouble of replacing the foam woofer surrounds. At the time I really didn't know anything about big floor speakers or audio equipment. In the years since I've become very fond of them and they've become a little worse for wear as I've moved them from place to place.

Each speaker has a left and a right and there's no difference between the left/right sides as far as I can tell. Cosmetically this grill mount model is a pretty close match to the original stock part. I did make some concessions for ease of 3D printing on the inside faces, but you have to take the covers off to see those.

In the photos the replaced panel is on the right side. Left side view added for comparison.

For those of you who use OnShape here's a link to the original CAD.

Print Settings

Printer Brand:

Prusa

Printer: 

I3 MK3S

Rafts:

No

Supports: 

Yes

Resolution:

0.3

Infill: 

10% Gyroid

Filament: California PETG PETG Black
 

Notes:

This part was too large to print in one piece on my Mk3S, so I printed it in two

To ensure the best strength for the grill ribs you should print with no less than 4 walls and with bridge settings turned on.

With my Prusa I really only needed supports on the "top" 2-3 inches on the grill ribs side and around the unsupported curve of the front/rear fascia. Bridging took care of the rest. See PrusaSlicer screenshot for support locations.

Post-Printing

After cleaning up the support material, a little lite sanding on the faces of the split seam should be prep enough to glue the two sides together. I sanded it with a sheet of sand on a flat work surface and by moving the part, seem face down, against the paper. It is easy to sand too much off of one side/corner (so be careful), but this method does provide two fairly flat surfaces for gluing.

I used super glue (Bob Smith) to bond it together and binder clips to hold it in alignment while it set.

From there your part should be a drop-in replacement for the OEM grill mount.

Category: Audio