Make a set of floor standing speakers with it!
Intermediate - advanced woodworking
Assorted wood screws - #6 or #8
Drill & bits
Step 1: Layout Materials
Match wood grains if possible.
Stagger the pieces to give the joints more strength.
Step 2: Glue Pieces Together
Set them aside to dry.
Stack them on a flat level surface.
Step 3: Remove Flooring Nails
Step 4: Cut to Size
(Speaker components will vary, so measure twice cut once)
Step 5: Choose a Wood Joining Method
I went with a dado wood joint.
It was the least time consuming, and stronger than a lap joint.
Apply the joints to the edges.
Step 6: Determine Speaker Configuration
Here I'm using a tmm setup. (Tweeter/Mid/Mid)
Step 7: Cutting Holes for Speaker Mounting
I scored an open box plunge router for $30 bucks.
The circle template I had to make.
Find a scrap piece of clear acrylic.
Copy hole set of the plastic base plate onto the scrap piece of acrylic.
Drill out holes.
Temporarily mount the template (Scrap acrylic piece) onto a working surface
Using a compass and a ruler, mark your lengths from the center point of the router.
(This will be the center of your router.)
Drill location holes at the marked length... this will be the pivoting/spinning point for the router
Mount the new acrylic template onto the router.
Cut a test piece.
The pivot/spinning hole rests in a screw placed in the center of your workpiece
As you are cutting all the way through, be sure to have scrap material to raise your piece so you don't cut into your bench
Step 8: Start Cutting the Speaker Holes
To achieve different depth cuts (set the depth gauge on your plunge router)
This allow for the speaker to sit flush with the surface. (PIC 2)
Step 9: Cut Speaker Input Hole
Step 10: Test Fitting
before gluing the pieces together, I like to do a quick test fit.
to see if the dado joints are right.
Step 11: Transmission Line Tunnel (OPTIONAL)
This was done by creating series of internal baffles that reduce in size as it reaches the port at the bottom.
Read more about this type of speaker design here.
Use scrap angled cuts to reduce the amount of corners. (Enhances sound and increases structural rigidity)
Step 12: Ready for Paint.
I have left the sides open to do all the wiring and stuffing.
Step 13: Mask & Paint (Optional)
Lay down some paint.
Step 14: Baffling
Using liquid nails, adhere the side panel.
(Rest it on the glued side, the weight of the speaker should provide plenty of pressure for a good bond)
Step 16: Finish Assembly.
Step 17: Speaker Covers
Using some 3/4"x3/4" scrap lengths and circular router offcuts.
Create the speaker cover frame using glue and nails.
The circular router off cuts provide the strength.
Wrap the cover with some acoustic fabric.