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DIY Tough Bluetooth Boombox (Lasts 20hrs!)

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Picture of DIY Tough Bluetooth Boombox (Lasts 20hrs!)
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Get ready to build a tough & rugged boombox! "RaveBOX (v1.0)" can charge USB devices, play MP3s and tune to FM stations! It also comes with an IR remote offering better convenience. The boombox gives action sports and outdoor enthusiasts 18 hours of nonstop music. Whether you're at the beach, shooting rapids, or hiking outdoors, the boombox remains safe in its tough (Pelican-like) weatherproof shell.

How I Came Up With The Design:
It's been a while since I last posted my last boombox tutorial, it was pretty much a success but as we all know technology advances annually. RaveBOX is now as powerful as my old boombox but it's half the size of the old one.

I really had no design when I made this project, I had a "go with the flow" sort of vibe. One day I went to the mall to buy my usual supplies then suddenly I came across this generic Pelican-like case. They were selling it for like P480 ($9.60), I still had some speaker lying around, so I thought it would be cool to fit my four unused fullrange speakers + my 4" HiFi woofer. With no hesitation, I bought the awesome looking case. As I went back home, I started searching for parts in my inventory. I still had some amp chips lying around. I found two extra 2x3 Amp Modules (form dx.com) and my beloved Bluetooth Player Module (from dx.com).

All that's left is my battery, I wanted to make sure that my boombox would last a day of non-stop playback without charging, so I though of a solution! My robots are using LiPo batteries since they had a high "size to power" ratio, meaning they have a high mAh rating for their extremely compact size. Since the competition is still scheduled for December, I borrowed some of my LiPo batteries and decided to put them in my new speaker project.

Specs/ Features:
- 2.1 Channel Audio System (6W + 6W + 20W)
- USB Charging Capabilities (6600mAh)
- 18hrs Max Playback (LiPo Bat)
- Bluetooth 3.0 Audio Connection
- 3.5 Stereo Auxiliary Connection
- Equipped w/ FM Radio Tuner
- IR Remote Control

WARNING! You'll need some basic soldering skills, a little knowledge of electronics, and some patience to build this. Please don't blame me if you mess up the modules. SMD chips are very sensitive to over-voltage, handle them with extreme care! There's a lot to go wrong with this project. Good luck!

 
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Step 1: Tools & Materials

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Audio Modules & MISC:
- Bluetooth/ FM/ USB/ SD Player Module (w/ Remote)
2-Channel 3W PAM8403 Audio Amplifier (2pcs)
- Generic Watertight Container (Pelican Knockoff)
- 3 Cell 2.2A Lithium Polymer Battery (Turningy)
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Speaker Alternatives:
- 3W Fullrange Speakers (4pcs) [Alternative#1]
- 3W Fullrange Speakers (4pcs) [Alternative#2]
- 4" Woofer Speaker (8 ohms) [Alternative#1]
- 4" Woofer Speaker (4 ohms) [Alternative#2]
- 4" Woofer Speaker (8 ohms) [Alternative#3]

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TDA2005 Amplifier Parts:
Capacitors (25V) Resistors (¼w) MISC.
220uF (2x) 120K TDA2005 I.C.
100uF (2x) 2K Screw Posts
2.2uF (2x) 1K 100kΩ Pot
100nF (3x) 12Ω (2x) Heatsink
10uF (1x) 1Ω (2x)  
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Tools, Materials & Equipment:
- Rotary Tool (Dremel)
- Leatherman Multitool
- Portable Electric Drill
- Silicone Applicator
- 40W Soldering Iron
- Mini Hot Glue Gun
- Electrical Tape

Step 2: Measuring & Marking

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Get your vernier caliper/ ruler then transfer your speaker's measurements by using a compass & marker.

Step 3: Drilling & Cutting

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Here's my secret! Many are having a hard time making perfectly round speaker holes with a rotary tool. If you've ever heard of the "sanding drum bit", now is the perfect time to buy one. Start of by drilling a large hole inside your circular markings then sand of the excess plastic all the way to your markings. The Leatherman is sharp enough to cut the plastic, you can use it for the switch's hole. 

Step 4: Clean The Edges

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The rotary tool has left a jagged texture. Clear this off with your Leatherman's ultra-sharp blade then sand it of with a 300-grit sandpaper.

Step 5: Mounting The Speakers & Bluetooth Panel

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1st.)  Drill four holes for the woofer's screw mounts.
2nd.) Seal the woofer's gap with a bottle of silicone sealant.
3rd.)  Use superglue to mount the four tiny full-ranged speakers.

Step 6: Wiring Instructions

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Here's a detailed wiring diagram, it's easy and simple! :D

Notes:
- The Bluetooth module/ panel has an internal regulator (5-30v)
- Do not ground the speaker, they have separate lines
- They all share a common ground (negative wire)
- The PAM8403 amp module's "SW" pin is N/C
- Keep the wires as short a possible
- Observe proper speaker polarity! 
- Use thick wires for the mains

Step 7: Installing The Full-range Speaker's Amplifiers

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Mount the PAM8403 amp module on both Left and Right speaker array. Refer to the image above for the wiring instruction.

Step 8: Finding A Good 5v Regulator

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The PAM8403 needs a decent 5v regulator. The 7805 isn't enough to power two PAM8403 amp modules. Maybe it can, but by powering them with two separate 7805s. The 7805 is an outdated regulator, so better buy a 2 ampere USB car charger, it's much more effecient compared to having two 7805s. Plus the car charger's heat dissipation is much lower than the 7805s.

1st.)  Disasseble the cheap 12v USB charger
2nd.) Get the charger's circuit
3rd.)  Disolder the USB's female plug.
4th.)  Solder both PAM8403 amp module's 5v-input parallel to the 12v USB charger's 5v output.

Step 9: Mono Amp PCB Fabrication

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Since last year, I started using photosynthesized PCBs (presynthesized). It's much more cleaner and faster compared to the toner ink transfer method. You can still do the toner transfer method. The PCB layout (PDF) is provided below.

Learn To Fabricate PCBs: Click Here (Visit My Other Tutorial)

Step 10: Assembling The Mono Amp

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Follow the photo above for the part's layout. Solder them to their respective pins. 

Sorry! I forgot to flip my PCBs image, so I did the wrong side soldering method to get the pins right. Don't wory about the downloadable content, it's been corrected. If you are still confused, base the orientation on the schematic diagram.

Step 11: Combining L + R Channels For The Woofer

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Since we have mono woofer, the woofer should share both left and right audio signals. 

The L-Channel, as shown in the diagram, goes to your Bluetooth module's left audio out. While the R-channel goes to the right. The M on the other hand goes to your woofer's amp (audio-input). 

Step 12: Choosing & Installing The Battery

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I still had some LiPo batteries lying around in my workspace, I decided to use them for now. Lithium Polymer batteries serve as an excellent choice for long lasting power performance. The speaker can last for 18hrs @89dB, that's pretty good for an outstanding & punchy boombox. 

Remember, Lithium batteries don't like to get themselves drained for a long time, if they do, they bloat. And don't forget, they need special chargers, the ones with configurable LCD screens. Be careful with them and don't forget to do a monthly check on the battery!
ynze1 month ago

You put the charging unit directly to the lipo battery. So you can charge only 12V devices? What's the idea behind that? It would be cool to put a voltage regulator in between, so you can charge phones, psp's and mp3-players...

ASCAS (author)  ynze1 month ago

The charging plug is for the boombox's LiPo charger. If you look at the boombox very closely, the Bluetooth panel has a USB port. You can certainly charge any type of USB device (iPhones, PSPs, etc...).

can use microphone with this peoject?

ASCAS (author)  firdausharis2 days ago

Yes but you'll have to add a preamp circuit

can you show me the diagram of preamp circuit that can i include with this project

ASCAS (author)  firdausharis2 days ago

Here's a decent one.

dyn_mic.gif
Imad14967 days ago

nice boombox man but I want to use the mini amp 2.1 from dx (2x15watt(tweeters) 1x30watt (sub), do you know how much hours a 6800mah li ion battery can play music on medium volume?

What program did you use to make the circuit diagram?

ASCAS (author)  Awsomecp1737 days ago

Window's built-in "Paint"

phucyall1 month ago

Can you recommend a good alternative to the TDA2005 amplifier circuit you use that can be bought from DX or one of the other sources if I just want a pre-built one?

ASCAS (author)  phucyall1 month ago

This looks pleasing! It has a 2.1 channel setup. "Mini 2.1 High-Power Digital Amplifier"

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Just ordered one of these form DX. I will let you guys know how it works when I get it in the shop to test.

ASCAS (author)  John Culbertson1 month ago

Cool! Tell me if it's good, I'll buy one for myself too :D

Will do. Audio systems are new to me, so hopefully I will learn enough over the next few weeks to give a meaningful assessment. I have most of the build defined with the following hardware procured and in transit.

1. Surplus Geiger Counter Enclosure

2. The same Bluetooth module that you used

3. 2x Fountek FR58EX 2"

4. 1x Goldwood GW-204/8S 4"

ASCAS (author)  John Culbertson1 month ago

Whoa! I so envy your setup. Those Fountek fullrange speakers are so fancy. Plus, I've been planning to buy those Goldwood drivers for making speaker arrays/ towers.

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I'm super excited in seeing your write-up! BTW, Congratulation on the 123D :D

Congrats to you as well, and thanks for the great instructible.

Finally got the amp and the speakers, DX shipping is very slow. The 2 little Fountek's sound great on the L and R channels. I was able to induce some clipping in the Goldwood on the SW channel. I will toss it on the scope this weekend and get some more data.

phucyall ASCAS1 month ago

That's awesome. It looks like that amplifier outputs 2x15W and 30W for the sub-woofer. It looks like it produces enough power to drive all 5 speakers (2 of the 3W speakers from one channel) and I won't need any of the PAM8403 amplifiers. Since this one takes 10-18V input I also won't need the 5V regulator. Am I correct in these assumptions? I am trying to sort out the parts list now.

can you post the updates to the circuit

ASCAS (author)  phucyall1 month ago

Exactly! You are correct! I think that's the best substitute yet.

jhead7 phucyall1 month ago

I have the exact same question.

jhead71 month ago

I don't own a LiPo battery charger - does anyone know of a cheap one that would work with this project? Is there any other kind of battery that is capable of powering this boombox?

jhead7 jhead71 month ago

It seems like LiPo chargers are pretty expensive - I found the same Onyx one you have and it cost $79.99! So would there be any disadvantages to trying to save some money by using a $24 3800mAh 12V Lithium Ion battery pack?

ASCAS (author)  jhead71 month ago

You can buy a decent one from dx.com, around $29 - w/LCD.

There's not much really, the only disadvantage of Li-ion is its larger size, unlike LiPo you can get the same mAh for half the size.

tdizz0gg ASCAS16 days ago

Do you have a charger you can recommend from dx.com

ASCAS (author)  tdizz0gg16 days ago

I have a friend who has this charger: iMAX B6 2.5" LCD RC Lipo Battery Balance Charger. It was priced $25 before.

dada1121 days ago

Idol na kita ang bangis mo Hi-Fi King

ejonesss25 days ago

https://www.hobbyking.com/hobbyking/store/uh_viewItem.asp?idProduct=45020 is a much safer battery it has a bms built in to prevent over discharging

to be really safe use a 12 volt lead acid battery like ups and alarm systems use

kkuxer29 days ago
It looks very cool! I also have started my boom case, where all things I made myself
engdiong1 month ago
@ascas magkano yun? Taga Cebu ako eh. Pero pwede kong ka bili Sa cousin ko na nag tira Sa manila
ASCAS (author)  engdiong1 month ago

Yung lipo ba? Nasa P900 - P1.2k :))

wocampo ASCAS1 month ago
yung buong boombox magkano?
wocampo1 month ago
pwedeng bilhin sayo yan boss??
Awsomecp1731 month ago

Where did you get the tda2005 monolyphic amp?

Awsomecp1731 month ago

Are there any other enclosures that size, only that it doesn't look like a suitcase?

d-meister1 month ago

are you using the balancing plug on the lipo battery? It looks like they are tucked away in the pictures. If not do you think it will be ok to just charge it without balancing?

ASCAS (author)  d-meister1 month ago

Yup! Every time I charge, I open the case to access the balancing plug.

engdiong1 month ago
So I've been looking for li-Po batteries where'd you get yours?
ASCAS (author)  engdiong1 month ago

From a hobby store, located in a mall here in the Philippines.

engdiong1 month ago
@dagiles
Hey I've been thinking of the same thing... Hahah
I would really wanna make the speakers bt and apple remote compatible haha...
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