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Meet AirJam, the DIY Supercharged Bluetooth speaker. Ready your tools, we are making one from scratch! The previous "DIY Bluetooth Speaker (v1.0)" had some minor flaws so I listed all the possible improvements and built a version 2.0, named AirJam. It took a lot of sweat to build AirJam. 

Hacking & recycling helped me save money! Try to do the same :D

SMALL SIZE, BIG SOUND
Despite AirJam's tiny size, it has the ability to surpass its competitor's performance. Thanks to the sandwiched speaker orientation, I was able to fit 4 Full-ranged speaker drivers in one tiny enclosure (2x7x2"). A "passive radiator" was added to extend the lower bass frequencies, thus resulting to a much punchier bass. Compared to its rivals, the AirJam has 4 active drivers and one passive radiator, offering deeper bass and wider mids. 

CHANGE TRACKS WIRELESSLY (works with Siri!)
Thanks to Bluetooth 4.0, AirJam can receive Bluetooth transmissions up to 30 meters! Whether you are using your laptop, tablet or phone, you can easily switch tracks wirelessly. The handsfree feature works great with Speakerphone, Skype, FaceTime and also Siri! 

HIGHLY PORTABLE + WORLD'S LOUDEST PORTABLE SPEAKER
Love to go outdoors? The lightweight 2x7x2" acrylic enclosure makes AirJam easy to carry and it fits in your pocket! It's also great for sharing music with your friends. Unlike any other portable BT speaker, AirJam's quad back-to-back speaker orientation delivers 360° of fullrange audio. It chooses no angles and it's loud enough to move an entire flat.  

Based on our SPL meter readings, AirJam delivered 96dB of solid audio, making AirJam the loudest portable BT speaker of 2014. What's your basis? Boombotix claims that they have the loudest portable speaker, according to them, Boombot Rex maxed 94dB. This means AirJam is 2dB louder than today's loudest portable speaker.
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That design looks familiar! Humm... Where did it come from?
The design came from one of Bose's greatest masterpiece. It's the Soundlink Mini's Do-It-Yourself version. I based it on my original Soundlink unit (my dad's Christmas gift). If you would ask me: what's the best compact Bluetooth speaker in market? It's definitely Bose's Soundlink Mini! The only downside is the price, tagged at $199, it's not the average speaker that an average man would buy. So I thought of making a DIY version! 

If you remember reading my bio, you would recall that I love making DIY versions of existing HiFi products. The teardown is my favorite part since you get to learn engineer's secret on building their product's success. Luckily I didn't need to tear my Sounlink down since a lot of resources were cited online.

Specs & Features:
- Includes Handsfree Microphone (Speakerphone Function)
- Quad 3W Fullrange Speakers (4Ω - 35mm drivers)
- Quad 3W High Efficiency Amplifier (class AB)
- Li-Po Battery 1,300mAh (20hrs Playback)
- Command Buttons (Volume/Pause//Play)
- Tested dB (via SPL): 96dB @2ft
- 30m Bluetooth Range (v4.0)
- Single Passive Radiator
- 3.5mm Auxiliary Ready

Videos Comming Soon (after my condenser mic arrives): 
- AirJam Professional Ad
- AirJam vs. Bose Soundlink Mini
- AirJam vs. Jawebone Jambox
- AirJam vs. JBL Charge & Flip

Like Our Facebook Page, Get more updates!
Extreme Soundtest! That Will Blow You Away!
(Please wear HQ headphones. Hear the rich sound of the SUPERCHARGED speaker)

High Efficiency Amplifier Test (Prototyping Stage) 

Step 1: Parts & Materials

Parts, Modules & Materials:
- Bluetooth Speaker (for teardown)  -- [1x $7.60]
- 35mm Speakers (3W - 4ohms) -- [4x $2.80]
- 1Cell  LiPo Battery (3000mAh) -- [1x $8.70]
- Acrylic Board (0.4mm thick) -- [1x $5.00]
- 8002B Audio Amp I.C. (3W - 3Ω) -- [4x Recycled]
- 2.2uF Electrolytic Capacitor -- [4x local store]
- 10KΩ Resistor (1/4w) -- [4x local store]
- 33KΩ Resistor (1/4w) -- [4x local store]


Similar Alternatives (Read The Guide First):
- Bluetooth Speaker (for teardown)  -- [1x $12.60]
- Efficient 3W+3W Stereo Amplifier -- [2x $2.90]
- LiPo Battery Charging Module -- [1x $10.50]

Tools & Equipment:
- Rotary Tool (ex. Dremel)
- Leatherman Multitool
- Portable Drill
- Metal File

Step 2: The Acrylic Stencil Printout

Print the stencil provided by the link below. Carefully cut the stencil with a pair of scissors then trace the edges using a neon colored highlighter. Why use a highlighter? It's a lot easier to see when you are grinding and filing the edges.

Step 3: Sanding & Filing the Edges

You might want to get your rotary tool for sanding and grinding the larger chunks of acrylic. When the highlightered area gets thinner, start using your old metal file. 

Be careful, if you cut too much acrylic, you will have to repeat the whole process!

 

Step 4: Cutting the Speaker's Holes (The Hard Part)

Ohh no! It's time to cut the holes. I know how you feel. Luckily there's a technique to cleanly cut circular holes. 

1st.)  Again, use your highlighter pen to trace out your speaker's edges 
2nd.) Attach your grinding tip for your rotary tool then cut off the excess acrylic.
3rd.) Get your sanding drum tip then sand off the remaining pink marks.
4th.) Finally, bevel the edges. This helps spread the higher audio frequencies given off by the speakers.

Step 5: Mounting Your Speakers & Radiator

Okay, this part is crucial. In order to achieve that punchy bass performance, you must keep your BT speaker 100% airtight. Apply enough amounts of superglue on the acrylic's surface (speaker area) to ensure that you have sealed the gaps. Apply minute amounts of hot glue around the passive radiator & speaker drivers.

Step 6: Sandwich the Speakers

The side panels are not yet done. For now, the speaker's will act as the temporary foundation. Since both panels are completely congruent the speakers are also located at the same area (back to back). Use epoxy or superglue to bind them.

Step 7: Melting Acrylic - for Side Panels

I started off by supergluing the top panel then soften the acrylic by heating it with our kitchen stove. Don't forget, we still have to install our electronic components. We still have leave the lower panel open.

Step 8: Recycling Bluetooth Modules - Teardown

Here's the thing. I recently found a cheap Bluetooth speaker from our local gadget store, bought it for around 380php ($7.60). She's a real bargain! If you disassemble four of these, chances are you would end up recycling four 8002B amplifier chips (that's what I'm using).

Ordering a Cheap Bluetooth Module:
- Price range is around: $8 -22
- You only get the BT module itself

Ordering a Cheap Bluetooth Speaker:
- Microphone (Handsfree Function)
- Price range is around: $7-12
- 3W Speaker (35mm)
- Command Buttons
- 3W Amplifier Chip
- 3.7v Li-ion Battery
- Bluetooth Module

Step 9: Bluetooth Module - Hack & Mod

One can easily say that our previously torn-down BT speaker has a mono channel. We need stereo channels not mono, so are going to hack and mod the BT module. To do this, you must remove the capacitor pairs that are connected from your main BT module going to the mono amp IC, then replace them with wires (as seen on the photo). 

If you end up finding a different BT module, research its model and track down the L & R audio pins.

I researched My Module's Parts:
- Speaker: 3W Neodymium (35mm - 4ohms)
- Lithium Charger Chip: UN8HX
- BT Model: BLK-MD-SPK-D
- 3W Amplifier Chip: 8002B 

 

Step 10: Wiring Instructions

Here's a simple wiring diagram. Please read the image notes. 

Step 11: Button, Aux & Switch Extension

1st.)  Simply extend the buttons from your BT module to your speaker's enclosure.
2nd.) The aux, must be connect parallel to the BT module's audio output.'
3rd.)  Make the enclosure more airtight by filling the button gaps with hot glue.

What's the perf board for? How do I assemble it?
Well there's nothing fancy or complicated about this step. I just mounted the tact switches on a perf board for the wires to be organized. Just extensions. 


Step 12: Mounting the Battery + Battery Upgrade

I upgraded the 300mAh Lithium Ion battery (stock) with a much longer lasting 1,300mAh Lithium Polymer. Remember LiPo batteries last 4x longer compared to Li-ion batteries (in terms of size). 

The BT module came with a Lithium charging circuit. Don't worry it still works with the larger LiPo battery. The charger's auto cut-off is based on the battery's voltage and not on the current. So in terms of compatibility, the charger would still work with the LiPo, but in a much slower way. 

Speaker's Tested Battery Life:
- Bedroom Listening (low = 20 hours)
- Living Room (medium = 12 hours)
- Party Outdoors (max = 6 hours)

Step 13: Mount the Bluetooth Module

Before you hotglue the BT module to your speaker's enclosure, be sure to drill a hole for the BT module's micro USB plug.

Step 14: Fabricating the Amplifier

Have you decided, whether you should buy two "2x3W Amplifier Modules" or make one for yourself? If you don't have four 8002B chips, then better go with the ready made amp module. They only cost $2.90 each, plus dx.com ships them for free!

If your a Bluetooth speaker addict and has salvaged more than three BT speakers, then chances are you have four 8002B chips waiting for you to recycle. If you've managed to find four of those chips then, you could start making the PCB. I provided a downloadable PCB layout with fixed dimensions. The schematic will explain the part's value. 


Convert SMD Chips To DIP:Read My Guide 
My Full PCB Tutorial: DIY Customized Circuit Board


Mono Amplifier DEMO - Breadboard Prototype 

Step 15: Installing the Amplifier

Hot glue the amplifier in place, make sure it does not touch the "passive radiator". The wiring instructions can be found in Step #10. Goodluck! 

Step 16: Soldering the Speakers (Must Read)

The pin-5 of the I.C. goes to the speaker's negative terminal, while the pin-8 goes to the positive terminal. Polarity must be observed properly, otherwise all the speakers will cancel each other. 

Step 17: Sealing the Lower Panel

Finish off the airtight enclosure by repeating Step #7, but this time, we are melting acrylic of the lower panel. 

Step 18: Grinding the Edges & Sanding the Surface

Use your handy rotary tool to grind off those sharp protruding edges. Don't stop until you achieve a flat surface. Remember, the superglue used to bind the acrylic works as a filler (putty). It hides the gaps after sanding.

Step 19: Paint-Job Time!

Now for my favorite part. Express yourself with colors! I gave mine a two-toned finish (The famous "Black & Yellow" :D)

My Steps (You Could Do Your Own Steps):
1st.)  Stuff your Auxiliary Jack, Mic and Switch  with tissue paper.
2nd.) Cover the front baffle panel with masking tape.
3rd.)  Paint the side panels with a can of "Matt Black Spray Paint" 
4th.)  Cover the side panels with masking tape.
5th.)  Paint the side panels with a can of "Glossy Yellow Spray Paint"
6th.)  Let it dry under the sunlight for 2 hours.
7th.)  Unmask the tape.

Step 20: Customize!

Ok, now that we are done. Let us start customize our "AirJam" with anything! Adding vinyl stickers, painting stripes, laser cutting texts, you name it, let your imagination run wild! 

Suggestions (give me more guys!):
- Use Sugru to make AirJam's rubbery legs, it reduces vibrations. (The future needs fixing!)
- If you have an iPhone, play with Siri! AirJam talks back to you! :D
- Replace the dustcaps with parabolic platics (makes it look better)
- Try to find a cheap AirPlay module (loss-less wireless audio) 


Hey guys! I'm glad to inform you that we are building 3 more Bluetooth speakers this year! If you guys like it, your single vote would mean a lot to me! Thanks for visiting! Enjoy your AirJam!
<p>Thanks bro! I followed every link and I finally got it to work! :3</p>
<p>where did you get the passive radiator??? I can't find any that shape anywhere!!!</p>
<p>http://detail.1688.com/offer/42954391266.html?spm=0.0.0.0.72JKZt</p>
<p>How do you connect those two amplifier together? Please help. Thank You</p>
<p>I think this is from one of his other builds</p>
<p>were does the grnd wire go to?</p><p>is it connected to battery</p>
<p>Thanks sam, ASCAN doesn't give a good diagram of the bluetooth, switch, LED also.</p>
<p>where you buy those specs? <br>mind to give me links?<br></p>
<p>Could you give me a link to the passive radiators that you have. And the speakers.</p><p>THANKS!</p>
<p>Awesome! Are those dual passives? </p>
<p>Thanks for the help with the wiring, so difficult to find mini passive radiator, here's the only one I could find. I only use dual driver &amp; a passive radiator. input BT &amp; 3.5mm jack, built in battery &amp; charger.</p>
<p>Where did you found the Passive radiator? Any name? Was is just pulled out of speaker?</p>
<p>hello,</p><p>It is possible to have a shema? I don't understand the connections with the modules you advice In dx.com</p><p>The capacitors 104 have it mate sense ? where they must trendy ?</p><p>Thank</p>
<p>I like the look of yours even more:)</p>
<p>Nice! :D</p>
Would you be willing to take more pics of your build mini? I love that setup. Very clean. Debating whether I need a passive or not
<p>My mashup between v.1 and v.2. Took the electrical component list from v.1, and 52 mm speakers, a passive radiator and a larger enclosure from v.2. The enclosure is a 6&quot;x8&quot; project box that I scuffed with sandpaper to give it a &quot;weathered&quot; appearance. There is a connection LED between the two speaker, and the only two buttons are a push/push on-off switch and a momentary push switch for the mute. Currently performing the burn-in test. Sounds great so far!</p>
<p>Wow! I'm so envious of your build! Where'd you buy the woofer? You should make an instructable guide of your project. I'm very sure that you'll win a contest :D</p>
<p>LOL, Thanks ASCAS. I am but a mere hack that looks at a few projects and mashes them together. I do the same thing when using recipes for dinner! The passive woofer is a Peerless 830878. I found it at Parts Express. I will have to improve my powered speaker mounting. The hot glue has failed twice now. </p>
<p>I though it was a active woofer, LOL :)) Anyway, try to use Gorilla Glue. </p>
<p>Awesome, you should make Instructable how to make your own, does the Passive radiator help in this case?</p>
<p>My enclosure had plenty of bass. I almost think that the enclosure gives off as much of the lower tones as the passive radiator. FYI, I have seen where somebody has made a passive radiator from an old speaker. They removed the magnet assembly and glued a thick washer to the back of the cone.</p>
<p>Thick ''Washer?'' Anyway I'm gonna be making my own Mini-boombox, most likely I'll use your design rather than very long soundbar like speaker, though mine will be somewhat bigger as I will replace the Radiator with actual 4-inch woofer and use Amplifier board but I would very much like to see it around, or even video of how loud it is and what not.</p>
Here's my bluetooth module can someone help me figure out how to mod it ?
Got this bluetooth module from a cheap speaker but i can't figure out how to mod it, can someone help me on this one please ?
<p>what can I use instead of 8002b?</p>
My BoombeAt
<p>can you assist me. I found the mono channel(c21, c12) but when I hooked it to an amp I bought from amazon with 2 speaker outputs, only one works. The other speaker just hums. Thank you. </p>
Do I need any capacitor or resistor if I want upgrade first gen Bluetooth speaker ?
<p><a href="https://www.instructables.com/member/ASCAS" rel="nofollow">ASCAS</a> Hey Ive been attempting to make this however i cant find the L and R channels on my board can you help me? I'm so close aha just cant find them :( </p>
exellecent
<p>I try to find where to hack and mod my bluetooth module. I find this datasheet: <a href="http://www.mikrocontroller.net/attachment/285126/RDA5851S.pdf" rel="nofollow"> http://www.mikrocontroller.net/attachment/285126/...</a> </p><p>but I can&rsquo;t find where the Left and Right Pin are.</p><p>Can You help me finding what I have to remove to make it stereo?</p><p>Thank </p>
Can you please show the picture of 8002b amplifier
If you are from India like me and want a cheap Bluetooth speaker then this is it has a lot of features mic, passive radiator, 1 speaker, battery,SD card slot USB port and micro USB best speaker which I think and is only for around 7 dollars<br>
<p>sry, some links u supported is not working anymore......for the battery, its i have to buy 3.7v 3000mah battery?? I saw some battery is 11.1v 3000mah online, sry Im not really sure bout this thanks </p>
<p>Why is your battery covered in masking tape?</p>
<p>Did you rewire a 2-cell to a 1-cell or something?</p>
<p>or what if i yse an separate audio bluetooth receiver</p>
<p>if i am going to use the two amplifiers am i going to connect the two outputs together and then to the bluetooth as you show?</p>
Hi, the bliuetooth speaker from dx.com has a different bluetooth module.. It's reference is WS9621NLME. I researched the datasheet but can you help me for the connections?
<p>Connect the IC's 3rd pin to the amplifier's line-input.</p>
<p>Where to connect the Right &amp; left channel from the amplifier to the BT module?</p>
<p>Did you manage to find out where the L-channel and right channel connect to and from please?</p>
<p>No, sorry can't help you. I dropped the project as it wasn't working. I still have the PCB amp somewhere but don't have time to continue the project.</p>
<p>Did you manage to find out where the L-channel and right channel connect to and from please?</p>
<p>I have already made the amplifier (the PCB one) I just need help to connect the right &amp; left channel to the BT module because I am not sure where to solder them.</p>
<p>is there a Voltage Regulator in the bluetooth module ?</p>
<p>Wouldn't this just give you a mono input to the amplifier? Is it possible to get stereo output from this BT module?</p>
<p>Pictures of the disassembled speaker.</p>
<p>Some more images.</p>

About This Instructable

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Bio: Hi I'm Angelo! I am a 18 y/o college sophomore taking my majors in BS-ECE at the DLSU. I use my course as ... More »
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