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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

Picture of 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

Picture of 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

Picture of 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

Picture of 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

Picture of 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

Picture of 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

Picture of 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!
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ynze1 year 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 year 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...).

tiagos ASCAS7 months ago

So for the pcb amplifier ?

List of the capasitors, resistors etc? Please
broorb5 months ago

hello,

I tried making the TDA2005 mono amp, but I couldn't get it to work. I tried twice. I made sure that my PCB doesn't have any short. I followed all parts, except that I got the TDA2005R ( not TDA2005M ). I am not sure if this was the culprit. And man, did the IC heat up. I was using a 13v, 4A power supply.

Any help would be appreciated.

Thanks.

MikeA9 broorb7 days ago

When soldering components’ you should use a heat sink like an alligator clip between the component and the soldering to absorb the heat so you don't fry the component.

I tried to add a picture but the site wouldn't let me.

Divergence broorb2 months ago
Well if you haven't already put a heatsink! Cause otherwise that amp will screwed in no one from the heat :)
*no time

hi i have just seen your project and i think it;s brilliant what you have done so i was thinking of building on myself and was looking a your wiring diagram and was wondering instead of using the amp you built for the woofer could you just use another digital amp you used with the other speakers and if so do you need the resistors on that line if you could let me know i would be grateful

MikeA912 days ago

Fuses???

atmartin7622 days ago

hi i have just seen your project and i think it;s brilliant what you have done so i was thinking of building on myself and was looking a your wiring diagram and was wondering instead of using the amp you built for the woofer could you just use another digital amp you used with the other speakers and if so do you need the resistors on that line if you could let me know i would be grateful

tiagos7 months ago

If my bigger speaker got 3" instead of 4" does it change many things in the pcb amplifier Thank you!

QAZW tiagos27 days ago

no, just make sure your speaker can sustain the output wattage of the amp

julesoo72 months ago

we can make more powerful speakers
and we can connect a jack for electric guitar
excuse me for the lack of spelling I do not speak much English

julesoo72 months ago

hello

what is the total price when we bought everything

Divergence2 months ago

wait. don't you have to use a balanced charger with a lipo? in the wiring diagram you don't have one... only a dc charging jack? does this mean you don't need one...

ASCAS (author)  Divergence2 months ago

I already had stated that in step# 12. I guess you already know where to hook it up. :)

Divergence ASCAS2 months ago
Oh yeh my bad haha

where do you get the 2.2 uf 25v capacitors?

also where do you get the 100 nf 25v capacitors?

you can buy them from any electronics store, in australia i use jay car or altronics, try radioshack in america

thanks mate

Or they're cheap as on eBay or Aliexpress.com :)
AlfiaMak2 months ago

There is nothing wrong of surface mounting thru hole compoments on the copper side.

Dries-H4 months ago

What's te use of using 4 tweeters?

They're not tweeters they're full range
Divergence3 months ago
Great instructables man! Just wondering if this is a more expensive project than the Bluetooth speaker you made a couple of instructables ago and what are the advantages to this one? Other than being able to charge, use SD or fm
Matt2713 months ago
What capacitor did you use on those PAM amps

Hello. Awesome setup! Do you have an update and precise parts list?? Much appreciated!

George

ASCAS (author)  george.winstong3 months ago

Thanks. I showed pretty much everything in Step#1. If you're looking for a different BT speaker project, I'm working on a 3D printed version. Probably I would be finished by the last week of December then publish the guide on January.

Yes I would be interested! However, for now I want to build something for someone for christmas. I'll try with what you have and then build another with your updated version. thanks!

khilla23925 months ago

How Much does it cost to make this and if possible could you make one for me in black? Also how good are the speakers?

khilla23925 months ago

How Much does it cost to make this and if possible could you make one for me in black? Also how good are the speakers?

DangerousTim6 months ago

Awesome!

how much did this project cost?

nneracher10 months ago

at step 7 what resistor you solder on the module, is in the first picture of step 7. thanks

ASCAS (author)  nneracher10 months ago

It's a 470uF capacitor for filtering the line. It's done to prevent the buzzing sound.

ghamit ASCAS6 months ago

470uF at what voltage?

Radial?

tiagos7 months ago

HI !

Just on question why 2 HP per side ? what does it change if i only take 1 amp

where i put left n right Using this way only 2 HP

_ThaNerd_7 months ago

Where can I get the materials needed in order to make my own board?

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