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
Heres what you need:
1. One .50 caliber ammo box- http://www.joesarmynavyonline.com/servlet/Detail?no=5984
2. Two 4" speakers- http://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 plug- http://www.radioshack.com/product/index.jsp?productId=2062450
6. 12 volt illuminated toggle switch- http:// 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
Step 3: Remove the Plug from the 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
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
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
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!
For this step you will need a phillips screwdriver and a pipe cutter.
Step 8: Mount the speakers
Step 9: Attach wires to plug
for this step you will need: wire strippers, phillips screwdriver, soldering gun, solder, flux, helping hands, and safety glasses.