Constructing the SASS

Materials:

• 1/8 " sheet plexiglass© or lexan©

• 1/4 inch plywood

• 3/4 x 2" pine (2 each 5 inches long)

• sheet styrofoam  available as panel insulation ( I used 3/4" sheets)

• 1/4" plastic foam. (I used foam that was used to pack my computer motherboard when it was shipped )

• polyester fiber batting

• vinyl upholstery fabric

• Hole grommets ( I used DigikeyRP454-ND)

• assorted screws and bolts

Cut out two side panels from 1/4" plywood

Cut out two wing panels from 1/8" plexiglass or lexan. Drill holes for the bolts and hole grommets. Countersink the bolt holes. Clamp the cutout to a board and use a heat gun to soften the sheet along the line shown so that it bends at the desired angle. (These are the ears of the artificial head)

Construct the carcass by nailing and gluing the two plywood side panel with the 5" pine blocks. Do not use a hardwood since it would conduct sound too easily from one microphone to the other. Bolt the "ears" on to the carcass using flathead bolts.

Finishing

• Fill the cavity with the panel insulation

• Pad the outside with the batting and hot glue the upholstery fabric giving the SASS a rounded contour simulating a head.

• Glue plastic foam to the side of the "ears" to prevent sound reflection

• I spray painted the inside of the ears with black paint and fitted a piece of fabric-covered plywood as a back to the SASS