Repairing a Deformed Membrane:

When removing the fabric cover you may be surprised, as I was to find deformations of the speaker membrane. These are likely around the button restraints, which are visible through the fabric. These deformations are caused by the speaker being dropped on its face and remind one of the warnings on the shipping carton. They occur above and below the button as the wires hold the Mylar after being stretched. The wires could delaminate and cause buzzing when being vibrated against the Mylar. I can see the potential for Mylar fatigue from vibrating after being stretched. This may lead to a severing of the Mylar at some stretch fold. Leaving the speaker as is definitely not recommended. Magnepan regularly provides this type of repair service.

My deformations were displaced outward in excess of 1/8 inch, approaching a quarter. There was some twisting of the Mylar near the button edges as well. Less than an eight might be left alone, but it would be wise to check with Magnepan should you encounter this condition.

First you need the repair materials for a "do it yourself" approach. Telephone Magnepan and order the Molexane glue. Then get a small amount of Acetone and a can of 3M Super 77 spray adhesive. Don't try ordering the Molexane from Magnepan during the winter. Their truck service may park in the snow and frozen Molexane is ruined. They normally don't ship it until late April. You might get it elsewhere, but the quantity and cost might be too much. Magnepan charges $10.

A severely deformed membrane, well beyond the 2-inch area around the button requires more extensive repair than my inclination. Magnepan can loosen or remove the button(s) and delaminate the wire runs along their length using the Acetone. This permits taking up their slack at the end loops. There is danger in taking the buttons off as the screws can tear the Mylar. Straightening and aligning the wires over a long length requires something like the charging approach outline in my "Info from Magnepan" section. I would just send it back to the factory, myself.

First you have to delaminate the wires from the Mylar. Applying Acetone with an artist flat brush or q-tips you have to let the Acetone work it's chemical magic. Unfortunately, the Molexane is thick and very rubbery. It takes a while to get it loose, with multiply applications and rubbing with the q-tips. Loose pieces were stretched to break them loose using a round-ended tweeter. This stuff really stretches. It will take about 4 times longer than thought, unless I just didn't apply enough. Eventually the wires are definitely loose and the pieces cleaned off around the buttons. Magnepan recommends working on one area at a time in their literature.

About an hour later the membrane has returned to a flat condition. Now, you can prepare for their attachment. First their slack has to be taken up, enabling them to lay flat again against the Mylar. You want to keep them aligned and straight, particularly beyond the 2-inch diameter areas at the buttons. As this zone produces no energy to the membrane, wire deviations here do not effect performance.

Twisting the wires into something approaching a "Z" can be done with flat nose pliers or with a screwdriver that has a nick on its side to catch the wire. Holding it up off the surface protects the Mylar from damage when twisting. I would keep sharp edges away to avoid accidents. Grab the wires near the button and apply enough twist to get them flat again. Now they are ready to glue.

Gluing is a two step process. First, the 3M spray allows a quick adhering. You probably should mask off the work area, as it is easy to overspray this into adjacent areas. Taping some paper down so they don't blow up should be sufficient. Pulling up the wire allows surface spray to get to the membrane underneath. After it dries, in 15 to 30 minutes, you can check the wires and apply the Molexane. If you apply the Molexane too soon the volatiles will carry some of the adhesive up through the Molexane. This results in a tacky surface for many weeks depending on how soon you covered the 3M.

Magnepan's Molexane can comes with an application brush. You might want to use a slightly bigger one to smooth out the glue covering the whole membrane area treated with Acetone. They don't recommend applying excessive amounts. You can see adjacent areas to get an idea as the glue settles when drying. The drying time is longer. I wouldn't test your work for 12 to 24 hours to be safe.

Here is a view of the repaired membrane. The photo was brightened to show the small twisted wires near the buttons. Repair View

 You can see the puckers near the top button. You can also see overspray of the Contact adhesive to the left of the top button. Sorry the flash caused me to tweek the image. I hope it helps those in need.

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