Construction Manual Partybox - Build loudspeakers yourself

Construction Manual Partybox - Build loudspeakers yourself: partybox

Do you remember your first home improvement attempts? Who has not the speakers are collected from old radios and TVs, to lure them a little bass in wooden boxes made of wood? But most of the hobby loses itself with the first purchase of a "real" music system. Unfortunately!

Even today, it is still difficult to dispose of the cheap music system from the garden... if only the lousy sound were not. In almost all cases, however, this is only due to speakers made of plastic. These rattle, rattle and are not able to conjure even a little bass. However, if you put the speakers in a wooden case, the difference is phenomenal.

If we look around in the workshop, there are certainly still old speakers to find and with a bit of luck even a car radio. The combination is easy build a portable party box, with which you not only delight your guests at the next garden party.

Required work materials and tools

Shopping in the hardware store - prices individually

materialnumberDimensions
Leimholz2 (front, back)40 x 50 cm
2 (upper and lower part)20 x 50 cm
2 (side parts)20 x 36.4 cm
2 (radio separation)20 x 8 cm
1 (radio separation)20 x 25 cm
1 (separation)20 x 28.4 cm
Total glued laminated timber3 boards20 x 80 cm
1 board40 x 120 cm

Much of the material requirements for self-construction of the loudspeaker box can be safely covered by old stocks or replacement solutions. Fan grids may be around old power supplies and old speaker covers are suitable. The power supply should be tried a littlebecause not everyone is sufficiently suppressed and can cause humming noises. The power consumption of the car radio can be very different. In our speaker box was a power supply with 15 V and 1.6 A is sufficient. For a full load (very loud), however, more power is needed.

To find in the workshop or to buy online

materialnumberDimensionsprice
speaker3-way system or what existsOld Stock
car radioOld Stock
power adapter12V 2.5A (try it)Old Stock
Noppenschaumaround 0.5 m²3,60 €
Rubber feet in individual size4 pieces6 €
Pit corner guards (metal or plastic)8 pieces15 €
car antenna1 piece10 €
Fan grille (speaker or fan cover)2 €
div. screws2 €

tool requirements:

  • Table saw - Since all the boards used the original width of 20 cm or 40 cm, the cut can also be made in the hardware store.
  • Bench drill or cordless drill (a powerful drill is required to use a hole saw)
  • Router (alternatively jigsaw)
  • Cordless Screwdriver
  • jigsaw

Step 1: Preparing to build a party box

Construction Manual Partybox - Build loudspeakers yourself: construction

With some attempts the required size is determined.

Decisive for the self-construction of a loudspeaker box are of course the existing speakers. The construction manual therefore refers less to exact dimensions and more to the procedure.

The first step is therefore to try how the existing speakers and the car radio can be optimally arranged and how big the front of the self-built loudspeaker box has to be. The example uses a 3-way system with bass, midrange and tweeter speakers. There is also a car radio with DIN installation dimensions. This requires an area of ​​40 x 50 cm. It makes sense to stick to standard sizes of glued-wood panels, which are available in widths of 20, 25, 30 and 40 cm.

Construction Manual Partybox - Build loudspeakers yourself: construction

The tweeters and woofers are proportionately aligned.

When aligning the speakers it is important that the tweeters are at the top and as far apart as possible sit. The reason for this are the sound waves. High notes are delivered very straightforward and the speakers should therefore point in the direction of the listener. In addition, the high and middle notes form the stereo sound, so the speakers are arranged left and right. On the other hand, low notes tend to "roll" over the floor and can not be located. Where the woofers sit, so plays hardly a role.

So set up the tweeters as far as possible at the very edge out. The same distance outwards and upwards creates a uniform picture. Note, however, that there must still be room for the housing all around.

The woofers can as deep as possible and centered. Again, there must be room for a board thickness of 18 mm between the speakers.

Step 2: Mark the centers of the speakers

Are the four speakers exactly aligned, mark the holes with a pencil. These markings are not the later mounting holes, they are only for finding the midpoints.

Construction Manual Partybox - Build loudspeakers yourself: loudspeakers

1. To do this, connect the markers so that a cross is formed. The intersection is the center of the speaker and important.

Construction Manual Partybox - Build loudspeakers yourself: manual

2. To align the center speakers, draw a line through the detected midpoints of the woofers and woofers.

Construction Manual Partybox - Build loudspeakers yourself: partybox

3. Now measure the diameter of the cone of the woofers and woofers - the measure that later forms the cutout of the loudspeakers. Halve the measured value to find the radius.

Construction Manual Partybox - Build loudspeakers yourself: partybox

4. Draw the radii of the treble and woofers from the center of the crosses to the diagonals shown.

Construction Manual Partybox - Build loudspeakers yourself: manual

5. The midpoint between the two marks gives the later place of the midrange. Mark this clearly. The distance between all three speakers is exactly the same later.

Construction Manual Partybox - Build loudspeakers yourself: build

6. So that the car radio fits in symmetrically, draw a line through the midpoints of the tweeter and mark the center as a vertical line. The required section is now marked from the center line. Measure the height and width of the radio, halve the value and draw it from the center line up and down or to the left and right.

Step 3: Make cutouts of the speakers with hole saw and router

Tweeters usually only need a small opening, which can be easily made with a hole saw. The hole will be cleaner if you drill about halfway from both sides. Thus, the wood does not burst when the hole saw emerges and the sawed-off disc is easier to remove from the hole saw.

The same applies to the milling of the larger speakers. Again, it is It makes sense to mill only up to half the board thickness and then turn the board over. So the board can also be edited directly on the workbench, because the router does not exit on the other side.

Construction Manual Partybox - Build loudspeakers yourself: loudspeakers

Small holes can be cut out with the hole saw.

Construction Manual Partybox - Build loudspeakers yourself: partybox

For larger holes, a router is needed.

Becomes the cutout is milled out from both sides and rips off at the last delivery, a ridge stops at the rupture edge, which is then removed with the trimming cutter.

A flush cutter has a ball bearing, which is guided along the edge. The cutter above it has the same diameter as the ball bearing and thus adapts the remaining milling surface to the dimension of the bearing surface of the bearing. If the machining is done from both sides, the result is an exact angled and straight cutting edge.

Construction Manual Partybox - Build loudspeakers yourself: build

The cut leaves a ridge at the breaking edge.

Construction Manual Partybox - Build loudspeakers yourself: construction

This is removed with the trimming cutter.

Step 4: Saw a section for the car radio

The section of the car radio done by jigsaw, For this purpose, a hole is drilled in the corners to be able to dive with the jigsaw blade.

The exact dimension of the cutting depends on the dimensions of the radio. But it can also be used a DIN mounting frame, as it finds application in the car. The cutout is then 180 x 50 mm. The radio itself is often 1 - 2 mm smaller.

As a trial, the radio and speakers can be inserted and connected. However, do not be influenced by the sound produced. Without a housing, our self-made speaker hardly delivers any bass and sounds a bit tinny.

Construction Manual Partybox - Build loudspeakers yourself: loudspeakers

The hole for the radio is cut out with the jigsaw.

Construction Manual Partybox - Build loudspeakers yourself: manual

The first trial use of the speakers.

Step 5: Build housing for the speaker box

If the front is ready and the speakers have been removed, you can be started with the assembly of the housing. First, the frame is glued to the front and screwed. Whether this starts with the frame or the side panels are connected one after the other with the front, can be decided individually.

However, it is always helpful secure a board to the workbench and use a side rail (aluminum rail) as an aid. So the edges are flush and the rework is minimized.

Construction Manual Partybox - Build loudspeakers yourself: build

Lateral guide for easy positioning

Construction Manual Partybox - Build loudspeakers yourself: construction

The frame is finished glued and screwed.

Construction Manual Partybox - Build loudspeakers yourself: partybox

The front is put on.

Step 6: Place the dividing boards in the housing of the loudspeaker box

So that the air vibrations of the two bass speakers do not affect each other, is the space in the box is divided by a divider board. In addition, the radio must be excluded, since this needs to heat dissipation air openings.

Let's start with radio first. The given dimension of the small side parts must be adjusted individually. They must be so long that the larger horizontal board is exactly at the opening for radio installation. This is necessary to be able to store and fix the later built-in radio on it. This avoids it rattling.

Subsequently will the divider board inserted between the speakers and glued. On a screw connection can be omitted, since in addition all joints must be sealed with silicone. This provides additional support.

Construction Manual Partybox - Build loudspeakers yourself: loudspeakers

Insert partitions

Construction Manual Partybox - Build loudspeakers yourself: partybox

Seal all joints with silicone

Step 7: Install ventilation for the car radio

Some creativity is required for this step so we want to give up on specifications. However, it is important that the car radio receives a ventilation, otherwise it can overheat. Whether the ventilation is active or passive depends on the size of the ventilation holes and the given possibilities. Can be used computer fans, fan grilles, speaker grilles, perforated plates... What is currently in stock.

An active ventilation by means of computer fan has the advantage that the ventilation holes do not have to be so large and can be covered with a suitable ventilation grille. The fan (12 V) can be connected directly to the mass of the car radio and the connection for an automatic antenna. So he only turns on when the car radio is used.

If no active fans are used, should the ventilation opening generously designed become. For this purpose, even the entire area could be sawn over the radio and then covered with a grid or a perforated plate.

We opted for active cooling by means of computer fans decided, since this was available and the effort to install limits. However, this always requires two holes, which are at best arranged diagonally to each other in order to guide the air flow as far as possible past the radio. If the radio has a visible heat sink, the air extraction can be placed right here.

Construction Manual Partybox - Build loudspeakers yourself: loudspeakers

Installation opening for fan

Construction Manual Partybox - Build loudspeakers yourself: build

Fan bracket printed on the 3D printer

Step 8: Wire the car radio and crossover

If, as in the example, old speaker speakers are used, they are already properly connected to the crossover and the input only needs to be connected to the car radio. Has this ISO connectors, so open ISO connector can be used. They offer the advantage of being them compatible with many car radios and the radio can also be exchanged quickly.

The required pin assignment is usually marked on the car radio, but also standardized and found on the Internet. The radio itself is fixed with some silicone. This is certainly not the technically perfect solution, but provides sufficient support and prevents rattling of the radio.

Important is when fixing the crossover and the cable laying, that nothing loosely lies around. Rubber pads are therefore an advantage for the crossover. The cables can be secured with cable ties. The cable is laid through small holes in the partitions, which are then sealed with silicone. The power supply, the fan and the external antenna must also not be forgotten.

Even though it is only a voltage of 12 V, should someone take care of the connections, which has experience. Therefore, we do not want to go into more detail here.

Construction Manual Partybox - Build loudspeakers yourself: manual

Secure crossovers with rubber backing

Construction Manual Partybox - Build loudspeakers yourself: construction

Ensure good insulation of the solder joints

Construction Manual Partybox - Build loudspeakers yourself: manual

Isolate all unused connections

Step 9: Close the functional sample and housing

One last time a function test takes place and the speaker can be closed. This can be tested simultaneously, whether bass reflex ports can improve the sound. For this purpose, let music run, hold the back wall against the case and "ventilate" it a bit at times. You will notice a difference in sound. This is not a professional method, but we also build no HiFi, but a small party box. With bass reflex opening, the bass is usually somewhat amplified and richer.

For bass reflex ports, there is a special bass reflex tube, so that the openings are not just holes, but stick as pipes in the sound body. The holes for this are set with a hole saw in the side walls.

Was not forgotten the second vent hole behind the radio. Can the rear wall be put on now? The use of many screws ensures a good support and seals the contact surface. In addition, a silicone track can be applied to all frame parts prior to fitting the back panel.

Construction Manual Partybox - Build loudspeakers yourself: partybox

A bass reflex tube improves the sound

Construction Manual Partybox - Build loudspeakers yourself: manual

Do not forget the fan opening and screw it in place

Step 10: The exterior design of our DIY speaker

Of course, it should be thought beforehand how the party box should look like later. If only one coat of paint is used, it is advisable to paint the edges of the speaker openings before installing the speakers.

Since we provide our speaker box with adhesive film and the cut edges of the speaker openings are covered with self-printed grids, nothing had to be prepared and the application of the film can be done at the very end. We opted for black, because we want to set color accents with green speaker grids. Also the car radio receives on this way a new frame and a small kite becomes the eye-catcher. The advantage here is, of course, who has a 3D printer available.

A good contrast and protection form protective corners made of metal. This makes our party box really robust and professional. Although these ball corners form feet at the same time, rubber pads are still the better choice. We therefore combine both. So we achieve a good look and a perfect state.

Construction Manual Partybox - Build loudspeakers yourself: construction

Protective corners are practical - Rubber feet prevent vibration

Construction Manual Partybox - Build loudspeakers yourself: construction

A good color contrast attracts the eyes

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