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This instructable will demonstrate how to turn a .50 caliber ammunition box into a sweet set of speakers that can be used with your mp3 player, laptop, or any other portable device.

This set of speakers is rugged, compact, easy to take on the go, and LOUD!  The whole project will cost about $50.00 usd. and can be completed in an afternoon.

Step 1: Materials

Most of these materials can be purchased locally, but I chose to get some of the items online to cut down on costs.

Heres what you need:

1.  One .50 caliber ammo box- http://www.joesarmynavyonline.com/servlet/Detail?no=5984
2.  Two 4" speakershttp://www.amazon.com/Pyle-PL42BL-4-Inch-Two-Way-Speakers/dp/B000230LBI/ref=sr_1_2?ie=UTF8&qid=1291250695&sr=8-2
3.  2 sets of speaker wires- these will come with your speakers typically
4.  12 volt amplifier-http://www.dealextreme.com/details.dx/sku.34406
5.  3.5mm panel mount plughttp://www.radioshack.com/product/index.jsp?productId=2062450
6.  12 volt illuminated toggle switchhttp:// http://www.radioshack.com/product/index.jsp?productId=206249312
7.  Computer power supply- a broken one is ok for this, as you will just be using the plug and cord.
8.  Egg carton foam- I had this piece of foam from some type of packaging.
9.  1 3/4" desk grommet- these can be found in the hardware store or office supply store.
10.  12 volt power supply- this is the kind of power supply that a laptop would use.
11.  Two 4" computer fan grates.
12.  3.5mm male audio to rca audio
13.  3.5mm male to 3.5mm male audio cable
14.  cheap little tripod from the dollar store
15.  various hardware.

Step 2: Safety Gear

You are definitely going to have to wear safety glasses for this project as there are metal bits and solder flying all over the place.  I would also suggest wearing hearing protection because when you get ready to cut the ammo box, it may be the loudest thing ever heard by human ears.

Step 3: Remove the Plug from the Power Supply

Grab your power supply and remove the lid to expose the guts of the unit, this should be about 4 screws on the outside of the case depending on your model of power supply.  

Next remove the screws that hold the actual plastic plug in place, and carefully pull the plug out and snip the three wires that are attached to it. set the rest of the power supply off to the side. you will not be needing this for any other parts.

Step 4: Mark the Ammo Box for Hole Placement

Next we are going to mark the ammo box for hole placement. This is probably the most time-consuming part of the whole process, take your time here and do this part right, and everything else will fall into place.

These are the holes that will be cut into the box
1.  2 speaker holes
2.  Bass tube
3. Toggle switch
4.  4 holes for mounting the speakers
5. Hole for the panel mount audio jack
6.  4 holes for mounting the amp
7.  hole for the power plug
8  2 holes for mounting power plug

The dimensions of these boxes vary slightly, so I am going to show you an easy way to do this that will not really require me to give exact dimensions as to where to cut.

I have detailed this part of the process in each following photo, to be as clear as possible.

Step 5: Cutting the holes: Speakers and bass tube

To cut these holes you will need:
A drill bit 3/8" or larger in diameter
jigsaw with metal blade
round metal file
piece of scrap wood

The first thing is to put on your safety glasses so that you do not lose an eye. You need to cut a piece of scrap wood just long enough to fit in between the sides of the box (see photo). This will keep the metal from vibrating violently during the cutting process.

Step 6: Cutting Holes part 2: plug, audio jack, and screws

In this step we will be cutting the holes for the electrical plug, audio jack and the screw holes for the speakers as well as the amp.

for this step you will need:  Jigsaw with metal blade, drill with various sized bits, and a round file, I also used a deburring tool in this step.


Step 7: cut up the tripod!

The little dollar store tripod will be cut up and used for the standoffs for the speaker covers in this step.  This could be substituted by any tubular material of a similar diameter (1/4" ish).

For this step you will need a phillips screwdriver and a pipe cutter.

Step 8: Mount the speakers

In this step we will be mounting the speakers to the ammo box. Before you set your speakers in place, go ahead and mount the wires to the back.  Automotive speakers always come with the speaker wires in the box, and they are typically keyed meaning that the wires can only go on one way, there is a small plug and a large plug with corresponding small and large fittings. So go ahead and attach the wires and then slide the speakers into place with the wires laying inside the box for now.

Step 9: Attach wires to plug

In this step we will be wiring up the plug that brings the electricity into the box from the outside. this step is pretty straightforward.  Just take your time and use caution with all of the tools involved. and make sure nothing is plugged in while you are working on it.

for this step you will need:  wire strippers, phillips screwdriver, soldering gun, solder, flux, helping hands,  and safety glasses.

Step 10: Wire and install switch

In this step you will be wiring and mounting the toggle switch to operate the box.  You need the same tools as the last step so let's get to it.

Step 11: Wire up and install the audio jack.

In this step we will be wiring up the audio jack and installing it into the box. this step is very simple and is the last of the soldering required for this project.

Step 12: plug the amp in

Ok , all of the hard work is done, it is easy rolling from here on in.  In this step you are just going to be plugging the necessary wires into the amp.

Step 13: Install the grommet for the bass tube as well as the foam

In this step you will be attaching the grommet that acts as the bass tube, as well as the sound dampening foam, which will help the box not sound like a metal box.

Step 14: install feet

I went and bout some self adhesive feet for the bottom of the box not only does it help with vibration but it makes it not mar the surface that it is sitting on.

Step 15: adjust your levels/ finished

ok so you are done!!!!! at this point you can just go ahead and tinker around with your bass levels and volume to get the desired sound you like. Just as a note the box sounds radically different with the lid open or closed. so when you are making your adjustments be sure to close the lid so that you can hear the full effect.  I hope you enjoyed the instructable and feel free to hit me with any comments or questions.


<p>I was inspired by your Instructable to create an ammo can speaker for myself. Like others, I took a lot of cues from the Thodio A-box. I built a 24v 6 cell Li-Ion pack using Panasonic 3400mAh 18650's that feeds into two seperate regulators. One regulated to 18v for the Hifimediy T1 amp and the other down to 5v for the bluetooth receiver board. I charge it using a Universal laptop charger. Run time at 50% volume is about 20 hours on average. Charge time is about 3 hours. Speakers are Pioneer TS-D1002R. The buttons on the front are wired to the bluetooth receiver and to add an original touch. I cut and glued 30-06 bullet casings to the buttons. The port is a 1 1/4&quot; PVC Sink tailpiece that I scuffed using a scotchbrite pad and painted to match the can. The can is lined with 1/4&quot; MDF (attached using liquid nail) that I sealed with a few coats of poly to prevent moisture absorption. Most of the parts were sourced from eBay and I have spent around $150 in parts. I am very happy with the outcome. I am planning to attempt a second can for under $100 using cheaper components(12vSLA battery, Amp+Bluetooth module all in one, and possibly cheaper speakers). I still have a few final touches to add before I am happy with the first. Thanks for looking. Let me know what you all think and if you have any questions.</p>
I really like your idea but how do you set up the battery and charger so it charges the batteries and powers the speaker?
<p>I have the positive and negative split coming from the battery. One set goes to the charge port and the other goes to a main switch. The adapter is capable of supplying enough current to power the speaker and charge the battery pack simultaneously. </p>
If you could show me pictures of the inside that would be great! I am a teenager interested in electrical engineering but I need some help
Finished up mine this weekend for around $75. Way better than the high priced obes out there for sale.
<p>How did you connect the battery up to the amp to charge? Thank you!</p>
I have the battery as well as the 12v A/C power supply port connected to a 3 way center off toggle switch. The battery is charged with a separate external trickle charger.
<p>Too Questions: 1. Why not connect the audio input directly to the MP3 input on the amp? 2. Any concern with the internal temp of the ammo box getting too hot and frying the power supply or amp?</p>
I did and it works fine
<p>Hi, I was wondering about that AMP you used in youre project. How did you connect the power supply and the battery to the board? Is there multiple power in connections on it? From what I can see, its just those 4 that are connected dirrectly to the battery.</p>
<p>Awesome Instructable and great project to make!<br></p><p>I decided to use a 30 cal box to make it a bit more portable, recess the speakers so there was less chance of damage and use some different parts that I had lying around. Other parts were:</p><ul><br><li><a href="http://store3.sure-electronics.com/aa-ja32472-1488" rel="nofollow">Sure Electronics JAB2 2x30W</a> amp sourced directly from Sure (with cable package)<li>Dayton Audio DS135-8 woofer<li>Dayton Audio ND20FB-4 tweeter<li>Roadkill brand sound deadener to line the box<li>12mm MDF panel for mounting speakers<li>Urethane adhesive for attaching the MDF pannel and sealing around it<li>20mm dia PVC pipe and elbow for port<li>3.5kHz 2nd order crossover. I had to custom build this to accomodate the impedance mismatch of the speakers - off the shelf ebay ones don't specify what impedance values they are for, so won't work correctly with drivers of the opposite impedance<li>Stainless steel mesh<br><li>3 x18650 protected lithium battery cells NOT off from ebay (there are plenty of bogus ones there - these are not to be messed with)<li>3 cell 18650 battery holder, sourced from ebay<li>15V laptop power supply<li>Battery charge control module sourced from ebay<li>Dacron acoustic stuffing<li>Power switch and 2.5mm DC power socket</ul><p>The sound is awesome, especially for something so small. Battery life was about 20 hours at a reasonably low volume. I plan to make a 6 cell battery pack for it in the future.</p>
Made one of these but in a big wooden ammo box to take to download festival last year. I didnt want to take any chances so it runs on 2 x 7ah sla batteries. I added a key switch and a 3 - way toggle switch to select mains or battery power. I also added 2 drink holders in the lid which are for a boat and a usb/ cigarette lighter.<br><br>With taking it to a festival i needed the extra battery power as theres no means of charging and its safe to say it lasted the full 5 dats and still had more to give. I added the key switch as a screw you if anyone stole it because without the key its not going to work plus the fact i threaded catinery wire round my tent and padlocked it all up. So while its took a bit of a battering its ideal for a festival or holiday.
Question, i am getting little to no audio out of my speakers even with both the amp and phone volume maxed out. Any ideas. Im pretty electronically inept so any and all suggestions are great.
<p>awesome!!!</p>
Buenas noches con una consulta que medida son las bocinas o altavoces
GOOD NIGHT TO REQUEST THAT MEASURE ARE THE SPEAKERS
<p>Also, is it advisable to add a 10A fuse?</p>
<p>I am by no means an electrical engineer (so this may seem like a silly question), but how would you wire the Bluetooth switch, AUX switch, USB and USB switch, Voltage meter and switch, etc.? Would you use more wire to split them off?</p>
I am kinda new to this kind of stuff, but is the amp the only thing that needs charging?
<p>Hey guys, given how much all of our friends loved these ammo can speakers, we've launched a small manufacturing company called <a href="http://www.ammoaudio.com" rel="nofollow">AmmoAudio.com</a> to build these at scale and perfect the sound. We were just reviewed in Military.com (here: </p><p><a href="http://undertheradar.military.com/2015/02/ammocan-x-you-want-this-bluetooth-speaker-built-from-an-ammo-can/#more-14860" rel="nofollow">http://undertheradar.military.com/2015/02/ammocan-x-you-want-this-bluetooth-speaker-built-from-an-ammo-can/#more-14860</a>)</p><p>and you can read all about our build on our site. Hope you like the aluminum control panel and switches!</p>
<p>[Disclaimer: I'm the guy who builds these] I can avow for the AmmoCan X version. Not as much fun as building your own, but they're very efficient. They'll run 24hrs on a charge, have very little distortion and a good amount of bass considering the size of the enclosure. Bluetooth up to 15m and you can charge your phone while you're listening.</p><p>I'll do an Instructable for them one of these days :-)</p>
<p>Great instructable. I've been gathering parts to build a few of these, but in testing all the pieces I noticed that the amp is getting really hot. After about 15 minutes the amp case was over 140 degrees and climbing. Anyone else have this problem? I thought it might be because my speakers are 4ohm and the amp is rated 8-20ohm, but it looks like the original instructable has the same setup. Any suggestions? Considering using the cooling fan from the PC p/s but I'm wondering if it would make too much noise. Or just get a 4ohm amp?</p>
<p>Maybe you could mount the amp to the side of the ammo box with some heat-sink paste and use the ammo box as a big heat sink? How hot is your amp able to go before breaking?</p>
<p>Has anybody made an ammo box speaker like this that runs on battery, but can also be plugged in to run off a laptop power supply? I am trying to come up with a schematic to do it using a DC Power Jack w/switching, but am having trouble finding out how to properly wire it all together (power jack input is tip positive, shell negative).</p>
i am making one that uses a 12v battery. so pretty easy to connect 12v power supply + charge battery at the same time.
<p>Can you give a schematic or drawing to show how you hooked it up? I'd like to do the same thing, but don't want to end up blowing anything up.</p>
i dont have one drawn up but could if you wanted. basically its just how you would hook up a car stereo (schematics always come with them) put instead of having the power from a car, the batteries and switch are in their place.
<p>Does anyone have any hints on wiring in the 12v rechargeable battery? I purchased a 12v 7.0 AH rechargeable with charger from Amazon:</p><p><a href="http://www.amazon.com/gp/product/B002NYN7EM/ref=oh_aui_detailpage_o05_s00?ie=UTF8&psc=1" rel="nofollow">http://www.amazon.com/gp/product/B002NYN7EM/ref=oh...</a></p><p>I also purchased a 12v digital display:</p><p><a href="http://www.amazon.com/gp/product/B00825NB24/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1" rel="nofollow">http://www.amazon.com/gp/product/B00825NB24/ref=oh...</a></p><p>I'd like to use a hybrid of the original design (use the computer plug) mixed with the battery inside. Basically, I'd like to be able to plug the charger into the computer plug adapter and charge the battery, then be able to unplug and go without having to connect or disconnect the battery inside. I'm ***REALLY*** new at this, so any help would be greatly appreciated! Thanks!</p><p>Here are a pica friend's build I'm interested in incorporating (he's deployed, so I can't ask him):</p>
<p>Is it necessary to ground the system?</p>
<p>Just don't try to take this on an airplance. haha.</p>
<p>where did you guys find to covers for the speakers? I have been hunting amazon and cant find it</p>
they are on the Power supplies that they ripped apart. old school power supplies have that goofy grill. Go to any computer repair shop and ask for old power supplies that don't work and see if those griles are on them.
<p>any electronics supply house like an industrial version of radio shack. they are cooling fan covers. not really spaeker grills.</p>
<p>this is awesome!, im doing this for my electronics project, however in order to do that, i have to build my own amplifier bit, anyone know where i can find a schematic for the one he uses? so i can copy it and therefore pass my project</p>
Ive had a need for a loud portable durable speaker for a few years and never could find one to buy that satisfied my needs and wasnt outrageously priced. Did a lot of research into making my own before stumbling across some ammo can speaker projects like this one and decided to make my own. <br> <br>Used a 50 cal ammo can which I applied a butyl sound deadening material to, some kicker 4&quot; speakers, Lepai t-class amp and a 7ah 12vdc sla battery that is most commonly used in home alarm systems with quick connects for a battery tender for recharging. Audio is connected to a 3.5mm plug with my ipod. I also did some subtle customization to keep the military feel with the blacked out nut washer combo and the graphic i made and trimming the speaker grills in flat white. <br> <br>The 7ah battery is a little overkill since this amp and speaker combo is very loud and efficient. Future mods in the next few weeks will include: <br> <br>-port tube hidden under the latch <br>-lighter battery pack (prob a 3ah li-ion) <br>-speaker feet <br>-bluetooth connectivity
<p>Thought I would come back a few years later to drop an update on this project.</p><p>I ultimately ended up ditching the .50 cal ammo can for a .30 cal can which is almost half the depth and almost half the weight. I also ended up changing to a dta-2 amp and a 3.8ah Li-ion battery pack along with bluetooth 3.0</p><p>This setup is about a 40% reduction in size and 60% reduction in weight without a significant decrease in sound quality and battery life is still killer.</p><p>The bluetooth range is pretty limited mounted inside the box but as long as its close by all is good.</p><p>After tons of tinkering and lots of parts swapping I heavily recommend this setup.</p><p>Links for components below:</p><p><a href="http://www.amazon.com/gp/product/B002IA9MYK/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1" rel="nofollow">http://www.amazon.com/gp/product/B002IA9MYK/ref=oh...</a></p><p><a href="http://www.amazon.com/gp/product/B007RQW5WG/ref=oh_aui_detailpage_o06_s00?ie=UTF8&psc=1" rel="nofollow">http://www.amazon.com/gp/product/B007RQW5WG/ref=oh...</a></p><p><a href="http://www.amazon.com/gp/product/B008AGQMQC/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1" rel="nofollow">http://www.amazon.com/gp/product/B008AGQMQC/ref=oh...</a></p>
How did you wire the battery into the amp. I have fried two amps now. I have a switch with an LED in it, From the battery the positive goes to the positive the ground to the ground. I cut the cable supplied with the amp and ran it to the switch directly. The all black wire ran to the ground on the switch, the black and white wire runs to the switched power on the switch itself. Am I missing something here.
Ok. I think I figured it out. I had the wires going to the amp backwards. I checked on a laptop 12 volt power supply with my multimeter and found that the inside of the plug was the &quot;hot&quot; side, and the outside was the ground, which is the opposite of the way I had my power unit wired.
Have you come up with a way of doing internal bluetooth? I've been kicking around that idea for months and cant get around the notion that a bluetooth receiver inside a sealed steel box would have a range of about 14 inches, haha. <br> <br>I have found lots of simple solutions on bluetooth receivers, some even run off of 12v so they could be wired to the battery... but the range problem still eludes me.
Ive contemplated the idea for my next one as well, and the only solution ive come across is taking a bluetooth reciever apart, finding where its internal antenna is and mounting/ attaching a wire or other antenna to it to run to the outside. <br> <br>My idea was to make a tiny hole directly next to the speaker and have a tiny wire (antenna) go around the outside of the speaker to hide it inbetween the speaker body and the ammo box. That way you have an external antenna for the reviever thats partly hidden, maybe completely hidden by the speaker mounting body.
I have had the same feeling, especially given that mine is lined in sound deadening material. Ultimately I decided that I will be using: <br>http://www.amazon.com/Britelink-Bluetooth-Audio-Receiver-Portable/dp/B0059M4G9K/ref=sr_1_3?ie=UTF8&amp;qid=1346078657&amp;sr=8-3&amp;keywords=bluetooth+receiver <br>although I have yet to order it. Small, good battery life, rechargeable, great reviews. The only reason I am even attempting this is because I am porting my box and will be mounting the receiver directly above the port. Hoping this will allow adequate signal transmission but who knows. I will definitely post an update once it is all finished and let you know about the range.
<p>I am thinking of making one, battery powered and adding a small 3&quot;-7&quot; tablet for music controlling playing so it turns into an All in one player. or using a Small First act Guitar amp for parts... </p>
<p>What are the dimensions of the bass port?</p>
<p>Great Instructable! I made these a while back and figured I'd post some pics of my own. I made mine so they could run off of AC wall power as well as an internal 12v SLA battery. I put a panel volt meter with a momentary switch on top to check the battery voltage. I also added a USB charge port on the side. Thanks for the fantastic Instructable!</p>
could you show more pictures in detail<br>
<p>Has anybody made an ammo box speaker like this that runs on battery, but can also be plugged in to run off a laptop power supply? I am trying to come up with a schematic to do it using a DC Power Jack w/switching, but am having trouble finding out how to properly wire it all together (power jack input is tip positive, shell negative).</p>
<p>Why not use a small battery or run it out of a cigarette lighter so it is portable?</p>
<p>Heres mine that I built to be super compact at 8lbs. </p><p>Been using for 4 days and battery sits around 12.4 since full charge.</p><p>List:</p><p>1. 200 cartridge 7.62mm box</p><p>2. Powersonic 9ah battery</p><p>3. Parts-express dta-2 30 watt amp </p><p>4. 4 2&quot; Hi-wave speakers from Parts-express(220uf hp filter)</p><p>5. 2 1&quot; Tweeter(10uf hp filter)</p><p>6. Dc jack/3.5 audio jack</p><p>7. Spare 12v 2a wall adapter for charging</p><p>8. Materials (wires, acrylic, heat sink, terminals, etc)</p><p>Future Mods: Bluetooth, 12v solar panel</p>
<p>Would using two 6.5&quot; speakers work?</p>
<p>Great instructable! When I made mine I took a few liberties with the materials. I reduced the size of the ammo can, custom spacers (couldn't find that tripod) and used a different power cord, but for the most part followed the great photos and directions you posted. I made this for a client who happens to be the owner of a gun range for whom we did some design work. So I added our company logo. </p>

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