It is quite a hard, complicated and long process but it is worth it.
Materials and equipment:
-MDF wood 6 mm thick.
-ply wood between 12 mm thick and 20mm.
- A Speaker kit (here is a link) which can either run on battery or mains current.
-1 x TDA2822M audio amplifer IC
-1 x 8 pin IC holder
-1 x 1Kohm resistor
-2 x 10Kohm resistors
-1 x 10Kohm dual potentiometer
-2 x 4.7ohm resistors
-1 x Red 5mm LED
-2 x 100nF capacitors, ceramic disc
-2 x 470uF capacitors, electrolytic
-2 x 100uF capacitors, electrolytic
-1 x 10uF capacitor, electrolytic
-1 x iPod cable
-1 x PP3 clip lead
-1 x right angle power switch
-1 x DC power socket
-2 x speakers (8ohm, 66mm) and connecting wire
-1 x deluxe stereo amplifier PCB
-Spray paint (primer and final coating) Which ever colour you want.
-Sander / Sand paper
- PVA glue and Alraldite glue.
-Drill and drill bits.
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Step 1: Making the Box
Then cut the hole for the speaker to sit in, in 2 of your 100 mm by 100 mm pieces of MDF. using a circle cutter make sure you use a circle cutter with a diameter a little bit smaller than the speakers diameter.
Step 2: Dice Holes
I used a size 19 drill piece for this, but you can choose which ever size you want. Do a few test runs on a scrap piece of wood so that you can set the deepness the drill goes in, do not make it go in to far. Make sure you are drilling the right amount of holes on each side so that it resembles a dice.
Step 3: Cutting/drilling All the Holes for the Electrics
Step 4: Gluing Some Parts Together
Cut them so that they can fit all around an 88mm by 88mm piece of MDF. Repeat this for the four 88 mm by 88 mm piece of MDF you cut out. Then glue the inner joints onto the 88mm by 88mm pieces of MDF using PVA glue make sure they are as close to the edge as possible, for this you can use scrap pieces of wood which you put around the sides but put some bee's wax on them so that they don't stick to the 2 woods you are gluing. Use G clamps to hold down the strips of ply wood and wait for the glue to set. It should look like picture 6 when done.
Once you have done that glue the front piece ( the one with the hole for the speaker in it) and the back piece onto only the speaker box that won't have the circuit board in it. Now sand down all the edges to make a perfect box.
Step 5: Painting
Step 6: Painting the Dots
Step 7: Making the Battery Cover
So now cut out a piece of MDF that is the same size as your hole and then place it into the bottom piece and line up the 19mm drill piece to cut out the dice dots again so that your battery pack lid (the MDF piece of wood you have just cut out).
Then glue the magnets, that will hold the cover on.
Step 8: More Gluing
Once you have glued it all together you may need to cover the electronic part and do a bit mor painting to make it look really nice and smooth.
Step 9: The Finished Product
I hope you like it and please ask any questions.
I would love to see your ones if you make any, so keep me posted.
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