Build A Pair of Stereo Speakers by billbob
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This instructable is a basic guide for building a pair of high quality stereo speakers. The process is not difficult but will require lots of time, patience and effort.

Here is an introduction to the few main parts of a speaker:

Speaker Drivers
This includes the woofer and tweeter. The woofer vibrates at a low frequency to create bass while the tweeter vibrates at high frequencies to create treble. more on how speakers work

Crossover Unit
This is a specially designed piece of circuitry that separates incoming audio signals into high and low frequency pass. All the low frequencies are sent to the woofer and the high frequencies are sent to the tweeter.

Enclosure
This is the box that holds the woofer, tweeter and crossover unit. It will take up the majority of the instructable.

This is my first instructable! Please leave comments. I am not an expert on this topic but I'll try my best to answer questions.

To get started, we need to decide which speaker drivers and crossover unit to use.
 
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Step 1: Choosing the Drivers

Firstly, we need to chose which drivers to use. Some things to think about when choosing your drivers are:

- where you intend to use the speakers
- what you intend to power the speakers with
- how much space you have or how big you want them to be
- how much money you have to spend

In my case, i will be using them in a relatively small college student room and power them with a 100 watt per channel receiver that i found in someones driveway (they were throwing it out and yes i did ask if i could have it). I have about 200 dollars to spend on the whole project.

I need something not too big but will produce a good amount of sound and came up with the following drivers:

WOOFER: Dayton DC250-8 10" Classic Woofer $26.20 x2 (one for each speaker) more
This woofer can handle 70 watts RMS and 105 watts max which is good enough for my needs. Its Frequency Response is: 25-2,500 Hz and with an Xmax of 4mm and SPL of 89 decibels should produce a good about of bass. Remember, the larger the woofer, the larger the enclosure will need to be.

TWEETER: Goldwood GT-525 1" Soft Dome Tweeter $9.50 x2 (one for each speaker) more
This tweeter can handle 50 watts RMS and 100 watts max which matches the woofer. Its frequency response is: 2,000 - 20,000 Hz and has an SPL of 92 decibels.

CROSSOVER: Dayton XO2W-2.5K 2-Way 2,500 Hz $23.07 x2 (one for each speaker) more
This 2-way crossover unit separates incoming frequencies at the 2500 Hz mark. So any sound with frequency less than 2500 Hz will be sent to the woofer and vice versa for the tweeter. This means you need to chose a woofer and tweeter with overlapping frequency responses so no frequencies will be lost while in operation. It is also possible to make your own crossover but i will not go into that.

The total cost of the woofers, tweeters and crossovers came to be $137.06 which is relatively cheap considering how expensive they get. I bought my drivers and crossover from partsexpress. They are very reliable as i've used them numerous times in the past.

Hopefully this step will help you chose the best driver for your needs. The next step will describe how to design your speaker enclosure (the box).
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nightarya says: Dec 24, 2009. 12:10 PM
Well, i finally finished making them, and they rock.
They're loud, and effective.
A sub makes them a lot better imho,
But anyway, here they are
(also, just my own 2 cents, but if you made those boxes a little bigger, it would have been far easier
IMG_0023.JPGIMG_0031.JPGIMG_0032.JPG
billbob (author) says: Dec 24, 2009. 2:04 PM
Hey Nightarya,
Those look fantastic!  I'm honored you used my instructable as a guide for your own speakers. Yes, I agree a larger box probably would have given better sound and also easier to build. Now that I think about it, my method was a bit brute force/primitive =P though, I am still enjoying great sound from these. I also bought a 12" sub to go with my pair and it does make it sound a lot better. I think one of the first albums played on these was In Between Dreams by Jack Johnson. By the way, any other suggestions/comments/critisizm that might make the instructable better? Again, thanks! and happy holidays!

frenzy says: Jul 23, 2010. 3:16 PM
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yobub says: Jan 14, 2013. 12:55 AM
need help, i intend to build a pair of dual-woofer, ported speaker box, 8" - yobub
Mr. walrus says: Feb 26, 2012. 9:35 AM
i would imagine using mdf for speakers, and not particle board
http://www.diyaudioandvideo.com/FAQ/Build/
Thunder6322 says: Feb 5, 2012. 11:11 AM
Does a speaker sound better when it is in an airtight box or has a front or back ventilation hole or whatever you want to call it?
mwwdesign says: Feb 10, 2011. 12:28 AM
Something you might want to add is that new speakers/drivers need to wear in - out of the box the rubbers are pretty stiff. Playing for a good few hours for a week or two and you will notice that they will sound markedly better once they are run in.

:)
billbob (author) says: Jun 24, 2011. 6:09 PM
Yes you make a good point. The same goes for headphones. Burn in time may be 40 hours or more. Thanks!
bowmaster says: Oct 16, 2011. 6:49 AM
Just blast some Skrillex. That'll soften them up quickly!!!
Taschenratte says: Sep 13, 2011. 4:55 PM
Nice one man! But would it not be better to glue them? In this case you wouldn't have to use the plastic wood because all edges are directly together. It worked in my case ;) see:
BlaueBoxen.jpg
Thereyouhaveit says: Sep 11, 2011. 10:15 AM
When i first saw your i'ble , i honestly thought your woofers were only 6" then i got shocked when you said it was 10" , how did your pictures make it look so small .... ( yes , i have 2" to 10" speakers ) including 5 tweeters .
adam 101 says: Jun 16, 2011. 2:27 PM
what did you use for an amp? I saw you said it was found but what is it?
billbob (author) says: Jun 24, 2011. 5:34 PM
For the amplifier I'm using a very old Kenwood receiver. Its probably 10 or more years old but it works well. It has 2 main channels that are 100 Watts each and some lower power channels for surround sound. Are you looking to power some speakers?
adam 101 says: Jun 27, 2011. 9:04 PM
yeah, I found some old speakers in my basement and found your instructable. I've been looking for something to power them but didn't want to spend much money.
smartrobot says: Jun 22, 2011. 6:49 AM
What are the frequency can ply through these speakers
billbob (author) says: Jun 24, 2011. 5:33 PM
You can play all the audible frequencies probably from 20Hz to 20KHz. Each type of driver has a more restricted range though
smartrobot says: Jun 25, 2011. 5:41 AM
Thank's
GWSC says: Sep 5, 2010. 5:36 AM
Box volume is directly related to a number of speaker parameters. To obtain the optimum performance from your driver you should use these parameters to accurately calculate the required box volume. Just choosing a box volume from a chart and making a box may give a reasonable performance but it is more likely to give a poorer bass response than what is possible. There are plenty of software programs or online sites (http://www.ajdesigner.com/) that can be used.
billbob (author) says: Jun 24, 2011. 6:13 PM
Yes definitely true. The bass performance of these speakers are not as good as I hoped it would be. In the future I will be sure to follow a more formal procedure for determining the box dimensions. Thanks for the input!
Exiumind says: Feb 21, 2011. 7:41 AM
Hmm how do i know the driver inductance in order to calculate the zobels components?
Maybe i'l try to build an active variable x-over..

thanks =)
billbob (author) says: Jun 24, 2011. 6:08 PM
Hey sorry for the slow response. The voice coil inductance and impedance are on the part description on the parts express page. For the woofer the inductance is 2.57mH and the impedance is 8 ohms. Did you build some speakers for yourself?
onlinemastering says: Mar 3, 2011. 10:02 AM
Speaker building is a joy, thanks for the nice article explaining. The important aspect is getting a good design from the outset. I have made a few pairs of speakers with mixed results. The box dimensions are very important. cheers : )

online mastering
billbob (author) says: Jun 24, 2011. 6:06 PM
Thanks! glad you liked it. I think if i build another pair in the future I will try to get the box dimensions more correct. I didn't really follow a proper procedure for calculating the dimensions here.
jedi2010 says: May 4, 2011. 1:23 AM
"100V non polar electrolytic capacitor"

Did you mean 100uf,,i think microfarad is the unit of measurement for capacitance?
billbob (author) says: Jun 24, 2011. 6:02 PM
Yes, Actually looking back at it I just realized that neither values are correct. It should be C=L/R^2=2.57mH/64ohm^2=40uF. Where L is the voice coil inductance and R is the impedance. Capacitors do have a voltage rating too though, so it would be good to make sure that the voltage rating is not lower than the output of the amplifier/crossover unit. Thanks for pointing that out!
maovi says: Jun 23, 2011. 8:37 AM
How is the bass.Booming or tight.
billbob (author) says: Jun 24, 2011. 5:31 PM
The bass isn't as pronounced as it should be so I bought a nice sub woofer from parts express to go with it.
jrigvd says: Jan 25, 2011. 11:46 AM
couldn't you solder the speakers before you screw them in place???

(sorry for my bad english, im just a student)
jedi2010 says: May 4, 2011. 1:15 AM
im thinking this also,since its tricky to solder in twitter or tight spaces..
dudewhatthehellman says: Oct 18, 2008. 2:50 AM
are these speakers passive? if not, could you show us how to make one? im in need of a cheap but good one for an mp3 player, cant seem to finda nay that fit that requirement, either bad quality or too expensive...
Tech Freak says: Apr 10, 2011. 10:10 PM
You can run your mp3 player through them with an external amplifier. Just connect the mp3 player's headphone jack to an extra line-level input on your receiver, such as a tape , CD or auxiliary port. (Not a phono port, the level is wrong and the RIAA EQ would completely trash the sound quality.) You'll need a stereo mini-plug to RCA adapter cable, available at Radio Shack or can be made at home easily enough.

Hope this helps.
billbob (author) says: Oct 18, 2008. 11:47 AM
yep these are passive speakers
dudewhatthehellman says: Oct 19, 2008. 4:35 AM
o great thanks!
Exiumind says: Feb 21, 2011. 7:04 AM
LOVELY studio monitors eh!
nice one =D
Pyrotechnic-Robot says: Oct 16, 2009. 3:15 PM
 So is there an air intake and outtake hole?
mwwdesign says: Feb 10, 2011. 12:25 AM
No, as he says, it's a sealed enclosure, as opposed to a ported one.
ueharaf says: Oct 13, 2010. 6:21 AM
(sorry for my english) What happen if you put the (-) negative cable on the positive output of the amplifier, it can destroy the speakers?
mwwdesign says: Feb 10, 2011. 12:23 AM
Not much except that you would be running the speakers out of phase (by 180 degrees), which basically means the cone will move in when it should move out and vice versa. Would sound mostly the same, except bass could suffer most.

Deliberately running speakers out of phase is used to stop standing waves in audio installations (high and low points in the room from speakers interfering with each other).

Hope that helps?
natman says: Jan 16, 2011. 5:12 PM
i think it would work as a basic microphone
zack247 says: Jan 28, 2011. 8:14 PM
I very much enjoyed reading this instructable, I am a music fanatic and all of my friends are too, having speakers like this would be very awesome!
If i can find the time i am definitely making myself a set of these!
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