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Hello Everyone

Another project on the go !

My parents has a small garden in their house.

Most of the time we spend there is pretty quite , all you hear are birds and the " sound of silence ".

I wanna change it !

I decided to build from Plexiglas ( as usual ) a pair of speakers , supported with the LEPAI amplifier.



Hope you enjoy
:)


Step 1: Shopping List

The things you would need for this instructable are:

Set of component speakers - JBL CS 5C 120Watt

http://www.amazon.co.uk/JBL-CS-5C-2-Way-Components-Speaker/dp/B004OXETYW


Plexiglas - a sheet of 80X80  + a small 30X80 Black Plexiglas
Aluminum Angles - comes in 3M length
Crossovers- i ordered 5 already ( for future projects )

http://www.aliexpress.com/item/Counter-down-l280-one-point-counter-down-second-high-quality-audio-speaker-counter-down-crossover/1137698502.html

45M of 2x1.5 wires for speakers ( approx 30$ )

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Bolts and Nuts ( 60 or so )
Silicon ( Clear + Black )
Drill +Drill kit
Saw + Special blade for Plexiglas
Electric driller
Dremel Tool + Dremel Kit
Clamps
Working Gloves
Caliber

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Moreover i decided to take it a step further and mod ( improve ) the Lepai amplifier .

I order from eBay a few Capacitors and a few induction coils .

All the parts i`m replacing according to recommendations of  www.diyaudio.com members ( they provide lots of manuals  )

Step 2: First Step - Cutting the Plexiglas

Lay the Plexiglas on a steady table , Grab it with a pair of clamps, mark the size of the cutting hole for the speakers

You need to make 2 pieces of this Plexiglas



Do see that i drilled with a driller a hole the size of the blade of the saw , and only then you can start drilling

Step 3: Finished Cutting the Front Panel

Just wanted to check that speaker sits ok inside the hole

Step 4: Use Dremel Tool to Smooth Internal Edges

Step 5: Cut Rear Part

One for each speaker

Step 6: Cut the Sides

Two sides for each speaker

Step 7: Use Sanding Paper to Smooth the Edges

Grab the Plexiglas on the clamps.

Take some sanding paper and smooth the edges

I also smoothed the edges using the Dremel tool

Step 8: Create Bottom Angles

Measure the size of the bottom part and cut accordingly 

Step 9: Finished Cutting the Plexiglas !


Step 10: With All the Equipment

Step 11: Cutting the Aluminum Angles

Step 12: Aluminum Angles Ready

Step 13: Drill Holes in the Aluminum Angles

In order to attache the Angles to the Plexiglas , i marked the places i want to drill , Grabbed the Aluminum Angles on the table using the clamps  and drilled it

Step 14: Checking the Alignment of the Angles With the Plexiglas

Step 15: Start Assembling the Speakers

Step 16: More Assembling

Step 17: Insert Woofer

Step 18: Insert Tweeter

Drill two holes for the tweeter above the Woofer.


Step 19: Create Additional Hole for the Wiring of the TWEETER

Using the DREMEL , cut a small narrow opening for the wiring  

After you finish with the cutting you can sand it with the DREMEL Tool also

Step 20: Tweeter Ready

Step 21: Create Bottom Enclosure for the Speaker Using Angles

Bought a bunch of aluminum angles ( 2 sizes )

 drilled hole in each of them ( measured the distance before the drill )  , and up we go

Step 22: Coffeeeee Break !@

Mui importante 

Step 23: Allocating the Crossover

Step 24: Soldering Time!!

The fun has arrived.

I just love soldering ! , it`s just fun !


The crossovers purpose is to receive from the AMP the output , take it , split it to High and Low frequencies and send it to the proper unit
( e.g Tweeter - High tones  or Woofer - Lower tones. )



Step 25: Soldering Finished for Tweeter

Step 26: Soldering Finished for Woofer

Step 27: Soldering Finished for Input As Well

Input in YELLOW

Step 28: Before Removing Nylon , Checking the Sound

checked the sound using my old AMP from my existing Boombox .

 the sound is OK for now

Step 29: Removing the Protective Nylon!

Step 30: Still Removing the Nylon

Step 31: Still Removing the Nylon #2

Step 32: Spacers for Crossover

Cut a small hose ( in the size of the bolts ) 

Place it between the crossover and the Plexi

Step 33: Solder Ending to the Speaker Wires to Connect to the Speakers

Step 34: Black Silicon for Internal Woofer

Since i don`t work in a factory , and the cutting is OK but not 100% accurate , there are small spaces between the Woofer and the Plexi.

this could damage the Acoustics ,and the sound in general .


Soooooooo , i took BLACK silicon , and made sure that it is 99% sealed


Step 35: Closing the Cover + Sealing It

Before we close the case , be sure to clean it a little , check that all the bolts are tighten  and in general that all wires are connected securely to the peripherals  ( e.g  speakers ,and crossover  ) 

Step 36: Add Small Reflex-Port

For the Acoustics sake , and for my good feeling , i will create a small ( 3cm ) hole  , this will act as a Reflex Port
 


BTW

Reflex-port uses to increase the efficiency of the system at low frequencies

Step 37: Still Reflex Port


Step 38: Add a Small Rubber Around the Hole

After finishing the hole , sand it a little , and add a small rubber housing , just for the looks

Step 39: Till We Mount Them - They Are Ready!

I have tested the sound using my Modded Lepai Amplifier.

The sound is absolutely awesome

The bass is great , and all this after a 20M (2x1.5 ) cable for each unit!

Step 40: The Lepai Amp Before the Upgrade !

Step 41: Modding the Lepai Amp

The Lepai amp , is one of the greatest amps on the market .

It`s cheap , and gives you a great value for your money

It cost between 15-20$ , and the sound is great , but not awesome!



So , you guessed it , i had to modify it , according to http://diyaudio.com website , i found a few forums with a lot of discussion on how and what to replace in order to say " Wow that`s a lot for 20$ "

I can actually say , that after replacing a few Capacitors , coils the sound has improved by 30% at least!
The bass is more responsive , and the power that it produces is much higher


Beneath you can see the old ( RED ) Output capacitors - there Value is :

63V .47uf +80/-20%
I have changed them to a : 250V .47uf 5% capacitors - way better!

Also i have replaced the Big capacitor .- which made the biggest improvement for the sound
The original Value is : 16V 3300uf 20%

I have changed it to :25VDC 4700uF !

Step 42: Prepare Plexiglas Case for Amp

I made an amplifier perspex cover.
Because of the new capacitors are higher, I would have to raise the lid. Eventually the situation was beneficial to the functioning of the amplifier, since now there are more ventilation for the electronic circuits

Step 43: The Amp

Step 44: Angles for Speakers

I had to mount the speakers in someway , so i decided to build a wooden speaker standUnfortunately I did not have too much time to spend it, so I just started to cut, made atangles to support the weight.Overall went well, very stable speakers

Step 45: Wire the Speakers

I bought around 40 meters speakers wires 2 mm thick
I started to wire the wires between the deck , and made sure that nothing is too tight, and I connected it to the speakers

Step 46: Completed!

Everything is ready!
Excellent sound, the sound is very clean, very balanced, and most importantly I am happy Comments are welcome :)
<p>Best article I have read on any sort of speakers, thanks for the contribution!</p>
Thanks dude!<br><br>:)
Very nice to read your article , very detailed and easily described
Thanks!<br><br>Appreciate it<br><br>:)
Excellent Job!! Very descriptive and a lot of great photos. I can&rsquo;t wait to try to make a pair myself. I like that you put links to your sources and showed your work. I like the mods to the amp.
Thanks!<br><br>Go for it , the best thing you can do is build it your self!<br><br>it`s easy to go to some shop any buy some prebuilt speakers<br><br>the best feeling is to know that you did something yourself<br><br>When you finish . upload!<br><br>Good luck
<p>NICE! One word of advice: Hex Head Screws. To make any sort of technology/electronics look top notch and professional, use hex head screws!</p>
Great job! Since i have zero experience i have a couple of questions, i am sorry if they will sound really naive :) <br> <br>First of all, step 33 is a little obscure to me...what are those ends? What do I have to solder? <br> <br>Also, i would need to place the crossover a little bit further from the tweeter, so those short wires wouldn't fit my purpouse. What kind of wire can i use? <br> <br>Thank you very much! And sorry for my poor english :)
Thanks!<br><br>That`s ok :)<br><br>On step 33 , you can solder the wires directly to the speakers<br><br>But if you will want to disconnect the wires in the future you wont be able to do so since it is soldered.<br><br>So the best thing to do is to Solder connectors to the wires and then connect them to the speakers.<br><br>those connectors can be disconnected when ever you want just by pulling the wires .<br><br>The best wires are 2mm thick , your would`t need more than that .<br><br><br>BTW<br><br>Your English is great!<br>:)<br><br><br>
Look good but to take advantage of a crisper sound I would have sealed the metal angles to the perspex with silicon and the mating edges of the plexi surfaces also siliconed. <br> The worst thing is that all the sides will &quot;drum&quot; &amp; &quot;colour&quot; the music. The easiest way to prevent this would be clear plexi cross braces top to bottom and side to side thus reducing the vibrating areas by 4. <br> To make up for the loss of internal volume to the box (calculated from your bass speaker specs right?) you can use a tank cutter to make large holes for air movement with out losing rigidity between planes. <br> <br>I am tempted to do this to match a plexi media Computer case but i would be using 25mm plexi and all the cross brassing I can muster <br> <br>
very nice!
Thanks! <br>:)
Very nice 'ible! That is some pitifully weak-looking coffee though
haaaa <br> <br>Thanks! <br> <br>The coffee is Turkish <br>Here in Israel we drink it a lot at brakes <br> <br>
Great project. I'm not sure I'd like go be any of your neighbours tho. Somebody else's music blaring over the garden wall would rank alongside the nuisance dog or wind chimes! :-)
Thanks! <br> <br>Don`t worry , we think about the neighbors , if we play music we make sure it`s the latest ;)
Well, dump question now... What about rain O&ocirc;, plastic case is ok, but do your speakers would really enjoy this, even without rain, just night humidity ? :s
I don`t worry too much. <br> <br>In Israel we don`t have that much of a winter. <br>either way i don`t take my chances, and i make sure that i cover the speakers with nylons before the winter. <br> <br>about humidity , nothing bad happened to the speakers till now ... for me if the speakers would hold in this position for 2 years or so i would be happy. <br> <br>
Nicely done and good references. I have one question. I've noticed a lot of audio instructables and plastic being used quite often instead of wood. Does it perform like wood for acoustics?
Hey , thanks<br><br><br>Absolutely no.<br><br>Wood is the best material , but it's not better looking then a clear plexiglass .<br><br>That's why, a lot of people choose plexi over wood<br><br>For me, the sound is great, I'm not an audiofil , so 100% it won't be! but 90% it is <br><br><br>Good luck !

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Bio: Hey! My name is Roey Leon, from Tel Aviv, Israel. On my free time, as a hobby of mine, I love building stuff from scratch ... More »
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