I wanted to construct a portable iPod speaker for when I was outdoors, possibly building something in my backyard, or even down the beach (without the need for a power outlet, or endless supply of batteries...) Up until now, when I have been in my backyard, I have had to fumble around with a stupid extension cord, run it out into the yard, plug in an old stereo and hope for the best. Even then, I get some music, but also ads... ads make me sad...
I decided to build myself something, as anything store-bought is simply a waste of money (and no fun!)
2 x 4" 16ohm speakers, gutted from a pair of Sanyo stereo speakers someone gave me on their way to the bin...
1 x 30 callibre ammunition box (bought from a displosal store for $7.95, not emptied by me on various people of choice)
1 x 3.5mm / RCA cable, with RCA plugs cut off, and wires stripped and treated
2 x 4" speaker grille covers with brackets
Various hardware, nuts and bolts, screws and washers that I had bought previously in a mixed packet from a hardware store
Step 1: Measuring and Cutting the Holes!
Okay, by far, the toughest part of this project is cutting the holes for the speakers into the tin.
First, I decided on cutting the holes a little smaller than 4", as I was originally going to have the grilles mounted internally... however the tin proved rather tough, so the holes were a little sloppy and sharp, so mounting them externally managed to cover up this mishap, and also helped it look a bit more awesome...
Make a template on paper, so the layout will be accurate, level and neat. Use a compass or something that is close to the right diameter, and draw the speaker shape onto the paper. I cut my paper to the size of the side of the tin, folded in half to find the centre, then in quarters to find the centre of each half. I lined the circle to this, then traced it on. You might notice a fold in the middle... This is due to the speakers coming too close to the edges of the tin, which would make the mounting a bit too difficult, so I crimped the paper i nthe middle to bring them in closer... Make sense? :D
Once the template is transferred to the tin, it is time to cut it out!
This involves pre-drilling for using a jigsaw / scrollsaw to cut the holes as neatly as possible into the tin. PLEASE use ear protection!! My ears are still ringing from it all, and its been 12 hours now... seriously, it's loud!