1) it was way too small. It needs to be at least twice the original size I drew it.
2) the material cost of a single part that big....
I've been working about 12 hours a day for all this week tweaking and refining my drawings and designs... I think I am finally happy with this base design.
I have gone through probably 30+ different renditions of the base for these speakers.
There have been a few major problems, that have made this base one of the hardest parts I have ever designed.
1st off, is the fact that it has to be big enough to keep the 8' tall towers from being pushed over too easily, and at the same time, keeping the base small enough to be ascetically pleasing (a 4" wide speaker with a 24" square base would look just ridiculous!)
Another issue is the fact that any part over 12" wide will cost TWICE the price for the materials alone. Aluminum "mini-plate" comes up to 12" wide at a reasonable price. As soon as you go over 12" the price almost doubles, when you have to go to a "sheet" (4 feet wide or more) So keeping the parts under 12" was pretty important. Also "shipping"... a 4" speaker with an 18" fixed base would NOT be very easy to pack and ship.
Oh-yeah... and it has to hold the 120 POUND speaker, without bending or breaking the base, AND have adjustable feet
So, the final design (for now at least) is made up of (3) parts. The main center section will be fixed to the extrusion in production, and the 2 front feet, can be installed by the customer with 6 bolts, before standing them up. I still have some "fine-tuning" to do to this design before any real parts will be made, but this is about 95% correct and finished.
Here's want I have to show for 100+ hours of revamping a design over the last 6 months