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I've got an old monitor wedge I wanted to gut, and install a Vintage 30.
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This is EXACTLY what I did with a Celestian G12H30 (which I prefer just a bit over the Vintage 30).
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The speaker is rated at 60 watts, right?
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Correct. The Celestion Vintage 30 is rated for 60 watts.
That depends on the speaker. Some speakers are 8 ohms. Others are 16 ohms.
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I may not know exactly how it works but logic says using a clients Mesa Boogie 100 watt head would drive the single speaker to all 100 watts. Would it overheat? Crack? Driven too much that it blows?
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Yes. It's not like if 61 watts flow through the speaker, it's going to immediately blow. You could blow up a speaker by playing 50 watts through it long enough on a hot day and if a billion other conditions are wrong. However, unless you are sending a sine wave to a speaker, it is never just sitting at 50 watts. It's constantly fluctuating. 50 watts is A LOT of watts and few 100 watt amps will actually send over 50 watts except for super short periods of time.
The watts part isn't really what is important. The fact that you have one little speaker that can be destroyed by a 100watt amp is VERY important.
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I've read some places that describe how to make iso-boxes,
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There isn't much too it. Just don't let the sound out. You just need a sealed container big enough to hold your mics and cabinet.
You can read on Guitar Fort thread where a dude built a huge fort and then cut a hole in it to let the guitar feedback and the outside volume of the fort went from 60dB to 90dB. Sealed is a BIG deal.
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that you can get reistors at certain ohms that will safely absorb some of the wattage.
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I use a THD Hotplate which I'm very very happy with.
Brandon