Cracking/Popping sound from Jeff Bagby's Baby Boomer

[daniel4381]

I bought a Baby Boomer Subwoofer kit from Meniscus with the PR option ( http://meniscusaudio.com/baby-boomer-p-1389.html ). I have constructed the cabinet exactly according to the build plan.
MDF is 3/4 inch all side except the front baffle is 1" (two 1/2 inch MDF glued togather). Inner dimension of the driver chamber is 10.5 sq inch and Plate Amp is put into a separate chamber and the wire hole is sealed properly. Top, back and the bottom of the driver cabinet is wrapped with supplied wedged foam.
When I first time connected the Sub and played a deep bass test tone, I found that the one of the PR making very odd rattling sound. I opened those again and found that the extra weight in the PR is loose and tightened both the PR weight and that rattling sound is gone. But, now when I increase the volume a little, there is a cracking sound from the PR and may be from the Subwoofer driver. It seem that the speaker can't take the load, but the sound is not high at all or the sub volume is not much, it is less then 1/4 of the volume. I thought that may be as it is placed on the floor and it happening due to the vibration with the floor. I stood up on the cabinet to reduce the shake and I understood that it is not happening due to the vibration, it is probably due to the PR. I have tested with my 2nd Sub (Yamaha SW160) and it does not make such sound. I opened the divers and found no physical damage anywhere.
The kit contains Dayton 1 x DCS255-4, 10" Woofer, 1 x SD300, 300W sub amp, 2 x Dayton Audio SD270-PR 10" Passive Radiator
A video of the sound is attached herewith https://drive.google.com/open?id=0B8LbK ... zRNOGZqY2s
Can someone suggest and help me out please.

[Wolf]

Are all of the seams in the box sealed well?
Are all of the drivers sealed well with gasket tape?

To me it sounds like an air-leak. I would remove each driver and check if the sound follows- at lower volume. Flex the PR's by hand and see if it rubs anywhere, or some glue joint has been released.

Later,
Wolf

[daniel4381]

Thanks Wolf, I found air is leaking from a mounting screw hole. I am going to change the Cabinet and seal the leak as soon as possible, let's see. thanks again

[Wolf]

Glad this helped you, enjoy.
Wolf