Speaker boxes are custom-built to the dimensions needed to get the desired result from a speaker. Boxes with holes other than to install the speaker in are called ported speaker boxes and require extensive knowledge about the speaker such as frequency and internal volume. Sealed enclosures are the easiest to build because they only require the dimensions needed to produce the best sound. The dimensions differ from speaker to speaker, but the manufacturer of the speaker includes these dimensions with its product.
Things You'll Need
- 2 pieces of 25-by-14 1/2-by-3/4-inch medium density fiberboard (MDF)
- Combination square
- Variable-speed drill
- 1/16-inch drill bit
- 3/8-inch countersink bit
- Wood glue
- 2 pieces of 16 1/2-by-14 1/2-by-3/4-inch MDF
- Phillips head screw tip
- A small box of 1 1/4-inch drywall screws
- Damp cloth
- 2 pieces of 16 1/2-by-23 1/2-by-3/4-inch MDF
- Terminal cup
- 3/8-inch drill bit
- Straight edge
Place the 25-by-14 1/2-by-3/4-inch MDF on a work table. These are the sides to the speaker box. Set the blade of the combination square on 3/8-inch. Put the long leg of the head of the combination square on the 3/4-inch edge of the pieces and draw a line on all four sides of the pieces.
Drill pilot holes on the lines with a 1/16-inch drill bit. Drill one pilot hole 1 inch from the corners of the MDF and the others 4 inches apart. Drill 3/8-inch-deep countersink holes in the same place as the pilot holes.
Put some glue on the 14 1/2-inch edges of the 16 1/2-by-14 1/2-by-3/4-inch MDF. These are the top and bottom of the speaker box. Place the glued edges against the matching edge of the sides and secure them with the drywall screws. Clean up the excess glue immediately with a damp cloth.
Lay the 16 1/2-by-23 1/2-by-3/4-inch MDF on the work table. These are the front and back of the speaker box. Center the terminal cup between the 23 1/2-inch edges and 4 inches from one 16 1/2-inch edge on one of the pieces. This becomes the back of the box.
Trace the pattern of the cup onto the MDF. Drill a 3/8-inch hole near one corner inside the pattern. Slip the jigsaw blade into the hole and cut out the pattern.
Position the straight edge on opposite corners diagonally on the remaining 16 1/2-by-23 1/2-by-3/4-inch MDF and draw a line from corner to corner. Repeat this for the other corners. Where these lines intersect is the center point from which to draw the circle for the speaker.
Set the compass at 7 1/8-inches. Stick the point of the compass in the center point created by the lines and draw a circle on the MDF. Drill a 3/8-inch hole inside the circle and cut out the circle.
Apply glue to the edges of the front and back pieces. Slip them inside the frame of the speaker box. Secure them with the drywall screws. Clean up the excess glue with a damp cloth.
Tips & Warnings
- Install the speaker before installing the terminal cup.
- Apply paint or carpet to the exterior of the box if desired.
- Do not leave power tools within reach of children.
- Do not apply a finish to the speaker box without proper ventilation.
- Photo Credit small speaker image by timur1970 from Fotolia.com