Step 1: Salvaged Parts
-Cedar box. I got this one at a thrift store for $.50. I've seen various kinds of pine(?) boxes at Michael's craft stores.
-A couple small hinges.
-A set of feet (adhesive or screw-in).
Step 2: Cutting Speaker Holes
What you really want: a hole saw. A 2.5" hole saw would have been over $20, but it would be fast! (time to cut: 1 min.)
I first tried doing this from the inside because I wanted to be able to see the box's sides; however, cutting out the holes from the inside risks splitting the face of the box.
So I switched to drawing the speaker outlines on the top of the box. BE SURE THE CIRCUIT BOARD CAN SIT BETWEEN THE SPEAKERS!
Without the hole saw, I tried cutting with just the saw but changed over to sawing radiuses, rough sawing the circumference, and then finishing with the X-acto and round file. It looks awful, was awful to do, and made me wish I had spent $20 on a hole saw.
Not perfectly round, but as good as I could do without the hole saw.
Step 3: Interior, Speakers Hole Covers
Step 4: Glue in Speakers
The circuit board will be glued to the opposite side of the box, but DONT GLUE THE CIRCUIT BOARD YET. I drew lines to mark where it would go and where I needed to drill holes for the knobs.
Step 5: More Holes! (button, Knobs, Etc.)
This was, ultimately, done thru trial and error. Lots of error! The volume and treble buttons were angled, so I couldn't drill straight holes, and then the LED and headphone jacks were on extended bits of circuit board -- higher than the knobs and power button.
BE CAREFUL NOT TO SPLIT THE WOOD!
I used the round file to smooth out my work.
The circuit board is still loose through all the hole-making.
The power and input cables also need a hole (bottom of box).
Step 6: Gluing Circuit Board and Speaker Cable
Since one speaker held the board, it only had the input cable (green, running outside the box) and the power cable (longer, gray, also running outside the box).
The other speaker, then, had a long cable that got sound from the board (gray). Ideally, you might cut and splice a shorter cable, but I had space and plenty of hot glue to spare!
Step 7: Hinges and Feet
Feet screw on.