Alas I only have a few poor quality photos of this build that don't show all of the construction details but I shall endeavor to describe the process. UPDATE: I was able to get some fresh photo's showing more details!
- Length= 24"
- Height= 10"
- Depth= 11.5"
- Pyle PLCDS200 AM/FM CD Cassette 50W X 4 Channel Head Unit
- 2X 5.5" Goldwood Woofers
- 2X 1" Dome Tweeters
- 1X 6.5" Dual Voice Coil Subwoofer
- 120VAC to 12VDC 9A Switching Power Supply
1 - 8' 1 X 12 Pine
1 - 4' X 4' X 1/4" Pine Plywood
1 - 5/8" Hardwood Dowel
4- Cabinet Feet
3 - Port Rings
Car Head Unit
2 - 5" to 6" Woofers
2 - 1" Dome Tweeters
1 - 6.5" Dual Voice Coil Subwoofer
1 - 120VAC to 12VDC XA Switching Power Supply
2 - 6" Expanded Metal Speaker Grills
1 - Telescoping Antenna
Router & Bits
Drill & Bits
Pneumatic Brad Nailer & Air Compressor
Step 1: Make the Front & Back Plate
2. Choose the straightest long edge to ride against the rip fence and rip the 24" blanks down to 10" in width.
3. Measure for component placement then draw the layout on the front plate and determine the location for the 2 cabinet partitions.
4. Measure for speaker port & access panel placement then draw the layout on the back panel, then transfer the partition locations.
5. Butt the bottom edges of the front & back plate together with the inside facing up making sure the ends are flush. Using a router equiped with a 3/4" straight cutting bit & a straight edge guide clamped to the blanks mill 1/4" deep dados to accept the partitions on the inside of the plates.
6. Layout the radius on the ends of both plates then use your router equiped with a straight cutting bit and a circle cutting plate to cut the radii in successively deepening passes until cutting through. Using this same router set up cut the holes in the front plate for the 5.5" speakers.
7. Using your router equipped with a rabetting bit with guide bearing rabbet the radiused ends on both plates on the inside to accept the bent plywood panels. Using this same router set up mill appropriate recesses around the speaker holes to accept the speaker flanges. Also with this set up mill the recess for the access panel in the back plate.
8. Using your router equipped with a 3/8" radius round over bit with guide bearing round over the outside corner of both plates.
9. Cut the opening for the head unit in the front plate using a jigsaw.
10. Use a drill equipped with an appropriate bit or holesaw to make the holes for the tweeters. Use this set up to make the holes in the back plate for the speaker ports.
I added a small recessed panel between the tweeters that I had planned to install a headphone jack and other goodies in, but as you see the panel is blank.