How to Build A Speaker Box: Make Custom Speaker Boxes: DIY

Nanjing Dual Cone Speakers
Nanjing Dual Cone Speakers

Ideas Behind Building Speaker Boxes from Scratch

My brother-in-law is a genius. The reason I'm saying that is because he learns and then makes things all by himself, best of all, what he makes all look like things you can buy off of the shelf. He's not a science person, he's talented in Chinese writing, calligraphy, Chinese seal carving, stuff like that, yet when he has to deal with science and technology, he reads information himself and implements them with common sense, amazingly, he never fails!

Because my sister likes to sing with Karaoke (we simply call it "K song" in Chinese), that is what got my brother-in-law into building his own homemade speaker boxes just so she and other family members could sing anytime they wanted, and it would save money too, just to think of it. So he ended up building several customized speaker boxes several years ago for my sister, they turned out to look and sound fantastic. I thought they were bought from a store at first. He even had brand labels attached to them and that indeed fooled me. Today I'd like to try my best to present how he built those custom speaker boxes.

PP Pod Nanjing Speaker (Dual Cone Speakers)
PP Pod Nanjing Speaker (Dual Cone Speakers)

Building the Speaker Boxes for Singing Karaoke

He happens to have a pair of polypropylene Nanjing dual cone speakers. Although the price isn't high, the quality is very descent, and the voice is so warm, quite ideal for singing Karaoke.

The Calculations:
It all begins with a series of tedious calculations. My brother-in-law is sort of computer illiterate, so instead of using a speaker design software, he has to go through his own silly way of calculation. You can ignore his way if you can find a good speaker design software online. A small calculator with arithmetic functions makes the process not too hard for him, fortunately. This speaker's Q value is 0.6, and other parameters determine it is appropriate to be a closed-box chamber, so he designed the box accordingly.

The next step is to saw a board. He uses the regular medium density plywood sheet due to its consistent physical characteristics and ease of processing. There are tools you need during the entire process.

Tools

The next step is to saw a board. He uses the regular medium density plywood sheet due to its consistent physical characteristics and ease of processing. There are tools you need throughout the entire process.

Electric Saw
Electric Saw
Misc. Tools
Misc. Tools

Cutting the Board to Have 90-Degree Bonding Surface

Restricted by the parameters of this speaker, the volume of the box has to be designed as 20 liters which is a bit too large for a 6.5" speaker pot. To avoid increasing the size of the box any further, he only adds an additional 1 liter space to be occupied by the speaker, and eliminates other normally required processes such as rebar and asphalt coating. Now it has to come down to the speaker box strength. Initially he has considered to cut the corners to 45 degrees so the bonded areas will be larger. But considering without rebar, screws can only be tightened on the board, as the result, the strength screws can bear on a 45-degree bonding surface would be a lot less than if it were screwed on a 90-degree bonding surface. So instead of cutting the board 45 degrees, he chose to make it straight 90 degrees.

The board needs to be cut precisely, pay special attention to the corners, make sure they are exactly square everywhere, including the side and ending facets.

45-Degree vs. 90-Degree Cutting

Square Side
Square Side
Make Corner Square
Make Corner Square

Open the Holes for Cone Speaker Using Wide Blade Circle Cutter

Cutting Tools
Cutting Tools
Opening Holes
Opening Holes
Face Board with Opened Holes
Face Board with Opened Holes

Proactive Actions for Late Stage Speaker Adjustments

Due to the fact that adjustments are needed in later stage, which require repeated demolition of the speaker box and face board, using just regular hex wood screws may result in damaged screw holes on the panel after all. My brother-in-law chooses to use machine hex screws instead, also glues nuts on the back of the panel so extensive demolishing process can be endured. Either building adhesive or white latex glue can be used for this purpose. A wood strip should be used to support the panels before the glue completely dries out.

Nuts Glued on Back of Panel

Panels Supported by a Wood Strip
Panels Supported by a Wood Strip

Secure Panels with Screws & Construction Adhesive

The Order of Glueing the Panels

Four side panels should be glued first, then the top panel on the loudspeaker side, inner treatments inside the box are to follow after. This includes minimum of two coating of glue, asphalt coating and adhere sound absorbing materials. Glue the top panel on the subwoofer side after all these are done. That way, since the hole for subwoofer speaker is much larger, doing the rest of the hand works becomes so much easier and convenient. This is very important to know ahead of time, or the inside treatments would become a hassle.

Putty Plastering is the Most Tiring & Dirty Job

Speaker Boxes with Putty Plastered
Speaker Boxes with Putty Plastered

Decorate Speaker Cabinets with Black PVC Veneered Sheets

The speaker cabinet without cover looks like a baby swan
The speaker cabinet without cover looks like a baby swan
Acrylic Cotton Does Not Seal the Speakers Well
Acrylic Cotton Does Not Seal the Speakers Well
Silicone Sealant is Chosen
Silicone Sealant is Chosen

Self-Made Sound Absorbing Material

Initially a kind of stretchable acrylic cotton was picked for sound absorbing. But it turned out this type of material did not seal very well on metal framed speaker cones, so in the end the silicone sealant was chosen.

First, squeeze out a thick layer of sealant into the grooves the same size of the holes for loudspeaker and subwoofer, wait for about 2 hours till the surface solidifies. After that, push the speaker down to pre-determined depth, and then let it stay until the sealant completely dries out. Do it for both speakers. Now you have a perfect matching sound absorbing speaker pad for each of your speaker. The drawback: you need plenty of sealant, but it's not easy to handle the extra amount; also, also this material has a degree of irritations to human body.

Hand Wind Inductor Coil
Hand Wind Inductor Coil
Hand Made Frequency Divider
Hand Made Frequency Divider

Finished Speaker Box

Finished Speaker Cabinet
Finished Speaker Cabinet

The Customized Speaker Boxes in the Theater

The Custom Speaker Boxes/Cabinets Part of the Home Theater Now
The Custom Speaker Boxes/Cabinets Part of the Home Theater Now

More by this Author


Comments 12 comments

AlanSwenson profile image

AlanSwenson 6 years ago from Las Vegas, NV

so you are building speaker boxes/cabinets...not speakers.


snakebaby profile image

snakebaby 6 years ago from Boston, MA, USA Author

I thought this was for speakers, then realized it was really for a box/cabinet. I do have a calibrating speaker part, wonder whether adding it to the hub would complete the building speaker part, but on the second thought just now, I assumed building a speaker really means building the electronic part, like building a dual cone speakers, am I right? I may change the title later so it doesn't mislead.


snakebaby profile image

snakebaby 6 years ago from Boston, MA, USA Author

Now I have to wonder what is considered "homemade speaker"? Who and how many would build the electric part from scratch when you can buy it online inexpensive? So I guess this hub should be good for both homemade speakers and speaker boxes. Any more clarifications? Thanks in advance


AlanSwenson profile image

AlanSwenson 6 years ago from Las Vegas, NV

I wouldn't make a homemade speaker, but I would change the title to reflect the actual topic.


snakebaby profile image

snakebaby 6 years ago from Boston, MA, USA Author

Thanks for the suggestion again. I went to search homemade speakers, yeah, I did find sites building them from scratch. And this morning it dawned on me that "speaker box" indeed refers to "??" in Chinese, the word I thought as "speaker" all along! It all makes sense now. Really appreciate your help.


Haunty profile image

Haunty 5 years ago from Hungary

Thanks for this useful hub, snakebaby! I counted and it looks like you might have to take away about 36 products or add 1800 words. Sorry. Surely, these changes must be in the best interest of hubbers, so I hope this will improve the efficiency of the hub.


snakebaby profile image

snakebaby 5 years ago from Boston, MA, USA Author

Thanks, Haunty, for looking into this. I discovered this change last night and did plan to fix my hubs. Hope there won't be too many. Too many things on hands and not enough time.


crystolite profile image

crystolite 5 years ago from Houston TX

Good hub with attractive pics,thanks for sharing.


KenWu profile image

KenWu 5 years ago from Malaysia

Superb DIY article! But I'm bit lazy to do all those things :)


snakebaby profile image

snakebaby 5 years ago from Boston, MA, USA Author

Thanks, Ken, normally we are all a "bit" lazy on building something from scratch :)


Ramon55 3 years ago

very nice work, we make speaker box's for car take a look at them.

https://www.facebook.com/MikesCustomBoxs


george dl 3 years ago

The tenor is very difficult to do.

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