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Replace rubber surround B&W (ZZ11436) woofer


Replacing Rubber surround of B&W ZZ11436 (DM 602 S2, DM603 S2, DM604 S2 & DM605 S2) woofer / midrange (and similar)

For this repair we used:

B&W ZZ11436 repair: tools used for the repair


A knife (not sharp) and some tissues will come in handy....
B&W ZZ11436 repair: these might come in handy


First check the situation around the magnet. With a number of woofers, the space underneath the spider is open and dust can enter the voice coil area. Cover this area using masking tape - later a lot of dust will be released during the repair.
B&W ZZ11436 repair: cover up the coil and gap


Carefully cut the edge away from the speaker cone. Make sure you do not cut into the cone!
B&W ZZ11436 repair: cut the surround from the speaker cone


Also remove the residue from the surround of the metal frame - the surround is relatively easy to remove. Below the rubber surround you will find a (white) special ring that allows to easily attach to the frame - leave it intact. The new surround will be glued on top of it later.
B&W ZZ11436 repair: remove the rubber surround from the speaker frame


Now remove the remains of the rubber surround attached to the cone using the dremel. Support the cone with one hand and remove the old surround with the dremel. Remove 5-7 cm surround at a time.
B&W ZZ11436 repair: remove the remains from the old rubber surround from the speaker cone


Everything gets black from the black dust. So stop if you have cleaned a few inches of the cone.
B&W ZZ11436 repair: clean the cone when it gets too dusty


Clean the front and back of the cone regularly with the large brush so you can see what you are doing.
vB&W ZZ11436 repair: also keep the back of the speaker cone clean


Because with a clean cone you can work much more precisely ......
B&W ZZ11436 repair: speaker cone partly clean


After treatment, the cone has been cleaned for 99% but is undamaged.
B&W ZZ11436 repair: the speaker cone has been cleaned


Make the outer edge of the cone a bit rough with a piece of sandpaper. We used P240.
B&W ZZ11436 repair: roughing up the outer rim of the cone


And make the cone completely dust free again. If necessary, you can degrease the cone. Also make sure the white ring on the frame is dust-free.
B&W ZZ11436 repair: clean the speaker cone


Apply glue to the inner lip of the rubber surround ... Shake the glue well before use.
B&W ZZ11436 repair: apply glue to the inner lip of the replacement surround


... and spread it with the supplied brush.
B&W ZZ11436 repair: spread the glue evenly


If needed you can mark the 'gluing zone' on the cone with a fineliner mounted on a 'spacer'.
B&W ZZ11436 repair: you might want to mark the 'glueing zone'


Apply glue to the outer rim of the speaker cone.
B&W ZZ11436 repair: apply glue to the outer rim of the speaker cone


Don't apply too much glue. Spread it out using the brush.
B&W ZZ11436 repair: spread the glue on the speaker cone evenly


Wait for the glue to dry a little bit. The glue will become a bit transparant.
B&W ZZ11436 repair: Wait for the glue to dry a little bit. The glue will become a bit transparant.


Now glue the inner lip of the rubber surround onto the cone. Support the cone with your other hand.
B&W ZZ11436 repair: Now glue the inner lip of the rubber surround onto the cone. Support the cone with your other hand.


Then put a weight on the inner lip / cone (not too heavy) so that the surround and cone stick together.
B&W ZZ11436 repair: if needed you can apply some weight on the speaker cone


An alternative weight ..... Let the glue dry for at least 12 hours.
B&W ZZ11436 repair: alternative weight applied


Now glue the surround on the white ring on the woofer frame. Lift the surround, and apply the glue. Repeat until the outer edge is glued to the white ring.
B&W ZZ11436 repair: glue the surround to the speaeker frame


You can press the outer lip of the surround gently. Be careful just to apply pressure so the glue will 'stick' and not move the surround horizontally.
B&W ZZ11436 repair: gently apply pressure


Apply pinchers around the cone attaching the outer flip of the surround to the frame. Put in such a way that the pinchers do not deform the surround / bulge or move the outer lip of the surround.
B&W ZZ11436 repair: cloth pegs will help you centering the voice coil


In close up....
B&W ZZ11436 repair: cloth peg in close up.


Four is the absolute minimum, more is better because your work is more precise.
B&W ZZ11436 repair: apply at least for cloth pegs, the more the more precise


Now feel, by carefully pressing the woofer downwards, if the woofer 'runs free'. You can also play a sound signal on the woofer for this. If this is not the case, center the woofer. Look for step 5 in the link.
B&W ZZ11436 repair: feel, by carefully pressing the woofer downwards, if the woofer 'runs free'


Then you can place a weight on the outer lip, or let the cloth pegs / squeezers do the job. The glue will have to dry again for 12 hours.
B&W ZZ11436 repair: you can apply some weight on he outer lip of the surround

Scary? Afraid to do this yourself? Please contact us, we can provide you with contact details of experienced service personnel for whom this is a piece of cake.

© Good Hifi VOF 08-07-2017