Introduction: Exotic-Wood Acoustic Marvel

Picture of Exotic-Wood Acoustic Marvel

Hello Dear Friends of the Instructable World!!!!

Today I have set out to create something beautiful both visually and acoustically. I assure you if you follow the steps below you will create an amazing piece that will last you for years to come. As makers I feel we have a certain duty to uphold to bring our passions into reality through the manipulation of tools and ideas.

Without any further ado, I give you the Acoustic Marvel:

Step 1: Tools Needed:

Woodworking Machines:

  • Band Saw
  • Scroll Saw
  • Belt Sander
  • Orbital Drum Sander
  • Drill Press and Bits

Hand Tools;

  • File/Rasp
  • 60 grit sandpaper-400 grit
  • Pencil
  • Scissors
  • Exacto Knife
  • Markers
  • Tape

Step 2: Materials

Wood:

http://ocoochhardwoods.com/

Buy eight total pieces of any type of hardwood you like in the dimensions 8" wide x 24" long and 3/4" thick and you will have enough to complete this project- be creative here with many varieties, or go all one single wood.

  • Walnut- $14.00
  • Mahogany- $14.20
  • Lacewood- $26.25
  • Curly Maple- $15.25
  • Maple Burl Blank- $21.00 (eBay)

Glue:

Other:

Shipping-$20.00

Total Cost (with Shipping): $136.72

Step 3: Begin by Designing Your Chamber (or Use Attached DXF's)

Picture of Begin by Designing Your Chamber (or Use Attached DXF's)

I began by sort of a trial and error in SolidWorks until I had a design I liked with multiple layers reflected in the various exotic woods used. My design was to fit an iPhone 6 with a case and that is what the hollow audio channel lines up for, however it does also fit an iPhone 7 engaging one onboard speaker.

The way that this project is designed, you will be able to swap out the phone holder piece for any make or model phone that you have, just take your measurements and apply the concepts show here.

All of the DXF's are actual size to create a 6" x 6" x6" Acoustic phone Speaker.

Step 4: Source Your Material

Picture of Source Your Material

After you have a design that you like you can source the woods that you want to use. Take your time and find hardwoods that you are partial to. I found I liked product from:

http://ocoochhardwoods.com

I went with Mahogany, lacewood, Curly Maple, and Walnut.

All 8" wide, 24" long and 3/4" thick.

It is also a good time to test out the final finish you want to use on your speaker so you can choose what order to glue your wood in later.

Step 5: Print the DXF's and Prepare Templates

Picture of Print the DXF's and Prepare Templates

This step takes a little bit of time, I had best luck using an exacto knife to get close to the edges and a scissors on the large runs. This will be your first chance to truly see how the entire speaker will go together when finished.

Step 6: Transfer Templates to Wood

Picture of Transfer Templates to Wood

Tape your now perfect templates for each of the sections to the parts of your wood that you would like to see on your speaker as show. Proceed to trace out the designs and remove the templates.

Be sure to mark which side of each piece you want to the front and which end is the top, some pieces look close to symmetrical, but are not necessarily.

Step 7: Saw, Cut, Grind

Picture of Saw, Cut, Grind

All blanks can now be cut out.

I used a large bandsaw to do my rough cuts, belt sanded the rough edges down, and finished the centers of each section with a scroll saw. Take your time here and get the circles cut just right.

An orbital drum sander works wonders on the interior of each piece.

Step 8: Test Fit/Admire

Picture of Test Fit/Admire

Layout all of your freshly created pieces in their rough cut form.

This is the best time for test fitting and making adjustments to various pieces.

Step 9: Dry-fit Your Speaker

Picture of Dry-fit Your Speaker

I had drilled two holes along the length of the interior of this project to install alignment dowel. This was perfect for helping me to line up and ensure my pieces would go together well.

Step 10: Create Phone Disconnect Piece

Picture of Create Phone Disconnect Piece

Transfer your phone template to the section that will house your phone.

Using clear packing tape and hairspray is a great way to attach a template with leaving residue.

First bandsaw/scroll saw the piece out. Then, using a guide, cut the two smaller side pieces away from the main body and cut out the area the phone will go.

There are many ways to do this step, use the pictures and your best judgment to create this piece.

Step 11: Clamp and Glue

Picture of Clamp and Glue

This is a fairly straight forward woodworking step. Glue and clamp each layer together, alignment dowels holding everything in place. Glue the phone disconnect piece separately as you want this piece to be removable when everything is done.

Step 12: Sand It Down

Picture of Sand It Down

After the glue had dried down, you can begin sanding. I started with 60 grit and went through all the appropriate steps up to 400 grit.

This step is based solely off how smooth you want the final product- remember that this is completely based off your own character and design choices! Make it rough if you want a rugged final product.

Step 13: Finish the Outside

Picture of Finish the Outside

I applied Watco Danish Oil- Natural to the outside of my piece. I like it because it dries fast and makes the natural grains present in the pop out.

Step 14: Turn the Center Baffle

Picture of Turn the Center Baffle

Setup a lathe with a nice centerpiece type of wood you would like to use. Here I have used a nice Maple Burl. Turn the piece into whatever desired shape you like, as long as it fits in the opening of your speaker.

Step 15: Test Fit and Finish Baffle

Picture of Test Fit and Finish Baffle

Here you can see the test fitting and what the maple burl looked like after it was finished with Watco Danish Oil.

Step 16: Install Rare Earth Magnets

Picture of Install Rare Earth Magnets

Mark and drill holes the same size as the rare earth magnets you plan to use in your phone disconnect. Using a two-part epoxy install the magnets in the top and bottom of this piece so that you can snap it in place or remove it at will when it dries.

Being able to upgrade your speaker in the future when you get a different phone is a huge benefit of this design, take your time ensure it is done right!

Step 17: Finish Pictures

Picture of Finish Pictures

A few closeups of the Final Result.

Step 18: A Brief Video of Form and Function

Picture of A Brief Video of Form and Function

See the video for an idea how this works and how much louder it can make your phone by redirecting music.

I apologize for this recording not being high quality.

Step 19: Finito!

Picture of Finito!

You have now completed your Exotic Wood Acoustic Marvel! Cherish it all the days of your life or give it to someone as a gift for them to love and enjoy!

Thanks for reading!

Comments

AH1GFLYR (author)2017-10-26

For those of you talking about Trobla and copying their design or idea, perhaps he should have mentioned me as well! My design, shared on FB a full two years prior to "Trobla". not only looked better, it sounded as good or better as well. Now, I'm not bothered by the Trobla copying "my idea"! "My idea" is a joke, with 7 Billion people in the world, the chances of creating something original are really far fetched. I think he did a great job of improving an acoustic process! People have been trying to improve that since the first caveman put two hands up to his cheeks, hoping to direct, and amplify, his utterance toward someone far away!

whiskymonster (author)AH1GFLYR2017-10-26

I agree.
Ten years ago, i used to drop my phone into a 12oz glass to make it louder. Not exactly new technology. The trumpet has been around for a fair while, and essentially it does the same!

Tuba Fett (author)2017-10-28

For those of you who have requested an updated video, I believe the link to have been repaired, please inform me if this is not the case.

LutherG (author)2017-10-26

Video??

ScottaBlanchat (author)2017-10-26

I think you used too much material, creating excessive scrap; it also resulted in unnecessary cutting. One should have used the factory edge of the wood blank so the remnants could be used for other projects.

Otherwise, danged ol' damn neat project.

dwight.christensen.7 (author)2017-10-26

It seems like there would be some distortion or reduced amplification because the layers of wood don't have a smooth 1/e**x curvature. Did you think about smoothing out the horn, instead of having the "stairsteps"? Or is that too much detail for not enough benefit?

bombicri (author)2017-10-26

Where is the video? I received "Failed - No file ... ????

Anshu AR (author)2017-10-26

Nice!
Loved it.
Can't wait to try it!!!!

swalton1 (author)2017-10-26

I see my Christmas just got smaller!!
I LOVE this idea and am excited to make this. Well done!!

Shawn F (author)2017-10-22

Nice job reverse engineering a Trobla!

https://www.kickstarter.com/projects/toktok/trobla...

JohnC430 (author)Shawn F2017-10-26

yeah, he should have mentioned the Trobla in his article. its ok to copy something, after all we all build on something that has been done before, but one also needs to give credit where credit is due.

joseph.campo.35 (author)2017-10-26

looks wonderful. The audio file looks blank though. I don't see a video that you mention either. Would you consider posting a video of how the phone fits in because I don't quite understand the principle. Great to see you used SolidWorks for the design. nice - beautiful stuff. Congrats.

DIY Hacks and How Tos (author)2017-10-21

That looks amazing! I love the look of the different shades of wood layered together.

About This Instructable

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Bio: Jack of all trades, master of some. Engineer by day, inventor by night.
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