Introduction: Hand Built Full Range Portable Bluetooth Speaker

Picture of Hand Built Full Range Portable Bluetooth Speaker

Hii everyone , In this instructable I will be showing you guys how to make a powerful full range portable bluetooth speaker from scratch. The reason why I built this is I hate using earphones all the time and I dont like the isolation it provides. I always wanted a portable speaker system which I could take to get togethers and parties .It also serves as an awesome entertainment system for your worktable. The reason why I decided to hand build one is because building things is my hobby and there was no way i was gonna convince my dad to buy me one ;). It gives you the freedom to implement your own design and modifications.

Guys, if you like my project , pleas do vote for me in the Bose audio contest , thankyou :) :)

This portable speaker consist of 6 speakers , two 2 inch 3 watt woofers, two 2 inch 10 watt fullrange speakers and two 1 inch tweeters.The top panel is made up of clear acrylic sheet basically to make it look cooler.The Transparent panel allows you to see the vu meter LEDs and the internal wiring and circuitery. An other advantage is that you dont have to drill extra holes to see the lights on the charging modules and other circuits

The speaker system has dual passive radiators to give it that deep long bass .The audio receiver board used supports bluetooth , usb and SD so it widens connectivity.It has a 10000 mah battery so that you can enjoy hours and hours of music without charging.The box is hand built using 5mm plywood and multiwood which I found in the basement.

Step 1: Sound Test

This is just a simple sound test which was shot using a smart phone, so the sound in the video might be a bit poorer than how the sounds and I am really sorry about it , I didn't have access to any professional cameras so ended up using my phone camera.

Step 2: Things You Will Need:-

Picture of Things You Will Need:-

1. 2 inch Full range Speakers X 2

http://s.aliexpress.com/nYrMVNFz

2. 2 inch mini woofers X 2

http://s.aliexpress.com/URvam6Vf

3. A pair of tweeters

http://s.aliexpress.com/IRFnaQfA

4. Passive radiator pair 40mm X 70mm

http://s.aliexpress.com/je2MzuQZ

5. 3.7 volt lithium polymer battery 5000 mah X 2 (18650 lithium ion batteries can also be used)

http://s.aliexpress.com/Ybiq6Zr2

http://s.aliexpress.com/URV7bUJv

6. Battery charging module TP4056 X1

http://s.aliexpress.com/VNfi26Bv

7. DC to DC step up module X 2

http://s.aliexpress.com/nArUNvEr

8. striped board

9. 1000 micro farad capacitor X 2

10. 4700 micro farad capacitor X 1

11. 5 volt amplifier PAM8403 X 2

http://s.aliexpress.com/yER3Yr6n

12. 5 volt VU meter(optional)

13. Audio receiver board with bluetooth, usb and sd support

http://s.aliexpress.com/ZbANJNrq

14. DC switches x 2

15. 5mm plywood sheet

16. 5mm clear acrylic sheet

17. 5mm multiwood sheet

18. 3mm female audio socket

19. Screws glue and other fittings

Step 3: Tools Needed:-

1. Screw driver

2. Soldering iron

3. Jig saw

4. sand paper

5. File

6. Drill ( hole cutting bits for the speaker holes, small disc cutting bit)

7. Hot glue gun

8. Scissors

9. Fevibond glue

Step 4: Making the Front Panel

Picture of Making the Front Panel

1. The full range speakers and one of the passive radiators is aligned on the 5mm multiwood to get a rough dimension of the front panel.

2. The final dimensions which was measured as 19 X 6 cm is drawn on to the sheet using pencil and set squares

3. The rectangular piece is cut out using a jig saw.

4. The center of holes to be cut is found by intersecting diagonals.

5. Two 52mm holes and two 32mm holes are cut using the respective wood hole cutting bits.

6. The excess wood in between the 32mm holes is cut out using disc cutting bit .

7, The piece is filed and sanded to perfection.

Step 5: Making the Bottom Panel:-

Picture of Making the Bottom Panel:-

1. Two parallel lines are drawn 8cm apart.

2. Mark two points 19 cm apart( length of front panel)

3. Two lines of 45 degrees are drawn from the two points towards the other parallel line.

4. The final shape is cut out using the jig saw.

Step 6: Making the Side Panels:-

Picture of Making the Side Panels:-

1. A rectangular piece of 10.5 X 6 cm is cut out using the jig saw.

2. The midpoint is found out by intersecting diagonals.

3. 3" holes are cut out from the middle.

4. Both the sides of the panel is sanded to roughly 45 degrees.

Step 7: Attaching the Panels Together:-

Picture of Attaching the Panels Together:-

1. The panels are first aligned then marked with a pencil the positions for screws.

2. Small holes are drilled at the marked positions 2.5 mm from the edges on the bottom panel.

3. Similarly , holes are drilled carefully on the side and front panels on the edges as shown in the pic.(These holes are drilled to prevent the thin plywood from cracking when the screws are tightened)

4. Glue like fevibond is applied on both the bonding sides and the panels are screwed into place.

Step 8: Making the Joints Airtight:-

Picture of Making the Joints Airtight:-

Hot glue is used to make all the joints airtight.

Step 9: Attaching the Speakers and Passive Radiators:-

Picture of Attaching the Speakers and Passive Radiators:-

1. Glue is applied on both the bonding surfaces.

2. The passive radiator and the speakers are pressed into their corresponding holes.

3. The joints are made airtight using hot glue.

Step 10: THE CIRCUIT:-

Picture of THE CIRCUIT:-

Step 11: Making the Circuit:-

Picture of Making the Circuit:-

1. The output voltage from the DC stepup is set to about 5.3 volt by turning the potmeter.

2. A 1000 uf capacitor is soldered to the output terminals of the stepup.

3. The 3.7 volt batteries are connected in parellel.(18650 batteries can also be used connected in parallel)

4. The other modules and the battery are glued to the bottom panel.

5. The charging module is glued such that the female micro usb socket aligns with the bottom back edge as shown in the pic.( Use the new version of TP4056 which has discharge protection too)

6. The 4700 uf capacitor is soldered parallel to the battery.

7. All the connections are made as shown in the circuit diagram.

Step 12: Making the Back Panel:-

Picture of Making the Back Panel:-

1. A piece of 5mm plywood is cut out according to the back dimensions, in my case it was 34 X 6 cm

2. The opening for the charging module is made carefully using a wood file.

3. The opening for the second passive radiator is drawn and cut out as explained in the front panel making step.

4. Both the shorter edges are filed from the inside until it fits perfectly with the side panels.

Step 13: Acrylic Top Panel:-

Picture of Acrylic Top Panel:-

1. The acrylic sheet is cut using a jig saw according to the top dimensions

2. Holes for the audio receiver board case and the tweeters are cut at the right positions.

3. Holes for the switches and auxilary jack is made

4. The tweeter , switches and the aux pin is fixed to the panel and made airtight using hot glue.

Step 14: Attaching the Back Panel to the Base:-

Picture of Attaching the Back Panel to the Base:-

1. Just like the front and side panels, the back panel is also attached by first drilling small aligned holes on the bottom and back panel , then its glued and screwed.

2. Before permanently attaching the back panel , Small blocks of wood with drilled holes is glued to it for finally attaching the acrylic top panel.

3. All the joints are made airtight using hot glue.

Step 15: Making Holes on the Acrylic Sheet for the Screws:-

Picture of Making Holes on the Acrylic Sheet for the Screws:-

1. The top panel is Kept in place.

2. The position of the holes to be drilled is marked.

3. The holes are drilled.

4. The drilled holes are countersinked using a bigger bit so that the screw heads wont protrude out.

Step 16: Adding Padding and Attaching the Acrylic Panel:-

Picture of Adding Padding and Attaching the Acrylic Panel:-

1. Here I used a foam based double sided tape as the airtight padding.

2. The double sided tape is cut and applied on the edges as shown in the picture( without removing the nonadhesive layer which exposes the second sticky layer)

3. The connection to the tweeters and switches are soldered.The wires to the audio receiver board is pulled out through the opening in its case

4. The top transparent panel is finally screwed to the rest of the body after peeling off all the brown protective covering.

5. The excess foam tape from the sides is cut carefully and neatly using a razor blade.

Step 17: Connecting the Audio Receiver Board:-

Picture of Connecting the Audio Receiver Board:-

1. A male micro usb pin is soldered to the power wires coming from the inside .

2. A 3mm male audio pin is soldered to the audio input wires coming from the inside.

3. Both the pins are inserted to the audio board and the setup is tested.

4. Once its working perfectly, the board is bolted into place inside its case and the case is closed using its own acrylic panel

5. All the holes are made airtight using hot glue.

Step 18: Finishing:-

Picture of Finishing:-

1. All the corners and edges are sanded to perfection.

2. Rubber bushes are added to the bottom of the speaker as the speaker sounds better raised a few mm from the ground .

Step 19:

Picture of

And there you have it , a powerful 6 speaker full range portable speaker

If you like my instructible , pleas do vote for me in the Bose audio contest.

Thank you :-)

Comments

rscanny (author)2017-10-18

Cool project, just ordered most of the parts for it now! How did you decide on the zise of the capacitors? And why are there 2 switches?

Thanks :)
I used two 16 volt 1000uf capacitor for each dc to dc stepup module outputs and one 4700uf capacitor parallel to the battery, the size usually doesn't matter much but the voltage should be above 6 Volt
I added the second switch as a power saving feature , it can be used to deactivate one of the amplifiers,. The speaker still sounds amazing just with full range speakers and tweeters when the speakers on the sides are switched off .
If you are planning to build one , I would recommend you use high quality 18650 batteries in parallel which has higer current handling capabilities

Antzy Carmasaic (author)2017-10-06

Nice design. I like the transparent top where the internal circuitry is visible.

One word of caution though: do not use LiPo/LiIon batteries in parallel or series. That's dangerous as it requires cell balancing which can be done by manufacturer only in most cases. Just buy a higher capacity battery.

Thanks :)
I tried it with single high mah battery first , but it didn't have the sufficient current eventhough it had a huge capacity( maybe because of the internal resistance) . But it's working perfectly once I used two smaller batteries in parallel.
Both the batteries have their own built in charge, discharge and current protection circuit which I think will protect the batteries to an extent.
Can you suggest me any alternatives for parallel battery protection?

You can use LiPo/LiIon batteries in parallel just fine. When you connect them, they need to be at the same voltage. You can use a TP4056 to charge them to the same voltage and then connect them. That is how you balance two cells and after you connect them in parallel they will never become unbalanced.

Using them in series is also fine, as long as you put overdischarge and overvoltage protection on each cell. There are BMS circuits on Aliexpress that you can buy that connect LiPos in series and protect them.

Thanks,
Glad I already did that before connecting the batteries in parallel. I fully charged both the batteries to 4.2 Volt using the charging module before parallel connection . Guess the battery are safe, :):)

KumanT (author)2017-10-09

Good design and handwork!

patrick panikulam (author)KumanT2017-10-09

Thanks :)

WXB (author)2017-10-03

Great post. Do you know the total cost of parts? Is there a list of specific part numbers and/or links to them? I saw a couple of links to speakers in your response to Willtato. Thanks.

patrick panikulam (author)WXB2017-10-07

I have added the links to the parts
The total cost I guess would be around $25 (₹1600) , but it came out cheaper for me as I didn't had to spend money on the box and the mini woofers

WXB (author)patrick panikulam2017-10-08

Thanks Patrick. Great post.

patrick panikulam (author)WXB2017-10-08

:-)

patrick panikulam (author)WXB2017-10-03

I will add the link to each part as soon as possible, I ordered most of it from Aliexpress so it was pretty cheap and I already had some of the components with me , so I didn't had to spend much

WXB (author)WXB2017-10-03

Also, I didn't read the entire list of instructions. Do you know or have you already posted the estimated time to complete?

patrick panikulam (author)WXB2017-10-03

It took me 5 days to build it , but I was only working on it for only a few hours a day with limited tools and all,. I think it can be finished in 2 to 3 days

tittiamo68 (author)2017-10-06

Compliments !!!

I'm already working on a similar project, I will use some ideas from yours.

I like shape and simplicity.

voted

Thanks :-) :-)
By the way, the radio alarm clock u made is just awesome

Surajit Majumdar (author)2017-10-05

Bro u did an awesome job.This Speaker looks very powerful. but if u covered it with vinyl paper then it will look more attractive.I really love this new design and I hope u win the audio contest :)

Thanks :-) :-)

vettebob (author)2017-10-03

What is the purpose of the three capacitors you added in the circuitry please?

Thanks!

CraigH23 (author)vettebob2017-10-04

Capacitors store power and release it fast as the amps demand it for the peaks. The power supply modules by themselves will be slower to react and the peaks will clip.

vettebob (author)CraigH232017-10-04

Thanks so much for your answer. I know what capacitors are and do, I just wasn't sure of the purpose here. Some have complained of noise/interference from the power supply using these amps, with varying degrees of success using capacitors to combat the problem. In my case, I am going to use this power filter: "Crazepony L-C Power Supply Filter 2A 16V Input Reverse Polarity Protection for FPV Racing Quadcopter."

Vettebob

It reduces the distortion in high volume

vettebob (author)2017-10-03

Very nice. I was already building something similar for my daughter. A WORD OF CAUTION FOR EVERONE!! Be VERY careful when adjusting the step up modules!! Wear face protection and keep the board/capacitors facing away from you. Two days ago, one of these exploded and pieces severely cut my upper lip, right through my mustache! Between the sound of the explosion and the impact, I thought I had been shot! Researching the device, I found this has been known to happen sometimes. The potentiometer can be sketchy, and while being adjusted can suddenly cause the unit to over volt, and explode the output capacitor. I am not saying don't use it, but if you do be very, very careful.

CraigH23 (author)vettebob2017-10-04

Wow, thanks, I use these a lot

vettebob (author)CraigH232017-10-04

Yes, do be careful with them. It was really as if I had been shot! The sound was as loud as a 22 pistol, and the impaact hurt like crazy. I don't know how to post pics here, but I have a "selfie" of my busted lip. Thank god it didn't hit my eye!! Polarities were correct; voltage was a regulated 12 volts. When I was adjusting the pot, it suddenly exploded the output capacitor. Subsequent research showed that this has happened to others. Use caution with them, and it wouldn't be a bad idea to replace that cap with one of 50 volts or more. It also wouldn't hurt to "cycle" that potentiometer fully in and out, then position it midway before you ever apply voltage to it. In any case, keep the board facing AWAY from you when first powering it up and while adjusting it. The darn thing almost gave me a heart attack!!

Vettebob

alan christo (author)2017-10-04

it is such a great work. I wanted to see videos of working of it. do those woofers have the power to shake things? what was the total cost? what is the benefit of making one instead of buying? why didn't you make the circuit of your own?thank you very much if you could answer them all. i will vote for you.

HAHA, they can shake your table for sure ;) All i had to spend on the whole thing was ₹1400, it came out this cheap as i ordered most of the components from aliexpress , in aliexpress the amplifier board costs only ₹19 each, dc step up ₹30 and the charging module ₹14, yup its that cheap but you should have the patience to wait for a month of delivery time. I found everything required to make the box in the basement, so i didnt had to spend anything for that.

The main reason i made it is because making things is my hobby ,i have been building things from 6th grade, Its much cheaper to build one and you can like do any design and modification that comes to your mind and you can show off your creativity too.

if the circuit is made by hand, its going to be very bulky and there is only limited space inside the box. And when i found that the modules are this cheap ,i went for it.

CraigH23 (author)2017-10-04

Nice design, well thought out. Nice instructable. Can I suggest your next addition to your work space be a vice? You look like you are trimming your toenails with a jig saw, and trying to get a blood sample from your finger with a drill ;)

Thanks:)
Haha, okay:-) i will be more careful with the jigsaw ;), .
it was difficult to drill a hole exactly through the middle of the 5 mm board with the board fixed in a position, so I did it by hands for small adjustments

hareeshgs (author)2017-10-03

Gr8 job Pat.Are you from Kerala?

Yeah , I am , haha how did you figure that out ?

maybe your name ;)

tpruitt3 (author)2017-10-03

Coming from someone who has been in the A/V industry my entire life, I would first like to congratulate you on your will and desire to make this and you did very well for a first time out.

On your next one, instead of hot glue, use Tite-Bond III glue as it bonds everything better, and, if you wait long enough, you wouldnt even need screws after the tite-bond III hardened. Also, very good using the passive radiators. That actually helps more than most people know.

Also, on the next one, if you want to clean it up a bit and make one that looks store bought, use a router to round off the sharp corners on the wood and plexiglass and use some acoustical pass through fabric to cover the front of the speakers. :)

I really enjoyed reading about your project and hope to see your future endeavors. Very good job!

Thanks :-)
I used fevibond glue before screwing it on , the hot glue is used just to make sure the joints are airtight
I will surely use tite bond on my next wood based project :-) :-)

MauricioO4 (author)2017-10-03

I Wonder why you say 26 watts? If the 8403 is rated 3W x 2, it would make a total 6W x2 in the load...

The full range speakers were rated 10 watts each and the other two were rated 3 watts each , so I thought their total would give the total wattage. Sorry if I am Wrong

Thanks for your answer, the wattage is mainly because the power the amps can supply to the load, the wattage of the speakers is the capacity they can withstand without suffering any damage, Thank you Sirfor your comment, Good project though,

:-)

Steinzel (author)2017-10-03

This is very nice! I voted for you.

Thanks :-) :-)

vettebob (author)2017-10-03

On mine, I am using computer fan "Finger Guards" over the speakers, because I KNOW if I don't, one of my daughters little cousins fingers will find their way right through those speakers!!

Haha,. I couldn't find ones of the right size at any of the local stores here, they don't have any for 2" speakers,. Their size starts from 3"

RobertS775 (author)2017-10-03

Super nice speaker! Very fine built. I just have one question. Where are the "26 Watts" coming from? The TDH0188N is rated 2x3 Watts at 5 V supply voltage according to data sheets. In this case it should be possible to get 2x(2x3) = 12 Watts totally, since two stereo modules are in use. Note that all engineers always talk about Watts RMS, or in other simpler words "continuous Sinus Watts".

Oh, I just added up the speakers wattages , 3+3+10+10,. Sorry if I am Wrong

loskop100. (author)2017-10-03

Very well done and detailed instructible but here is a tip for you when working with acrylic. Use pan head type screws instead of the tapered countersunk ones because the taper acts like a wedge and just a little too tight and it can crack the acrylic. To get the pan heads below the surface you can use a brad point bit or spade bit to create the recess and then drill the hole.

Thanks for the instructions :-), I will definitely do it that way next time

rudelhutze (author)2017-10-03

Great Job!

Voted!

It could use a little bit of paint in my opinion;-) but great Job!

Thanks :-)

NickS180 (author)2017-10-03

Awesome instructable, and hoping to see more from you in the future!

I'm curious how the quality and volume of this speaker compares to the 40W whiskey container setup you made previously. This has less power going to it, but it looks like a better design. What are your subjective impressions of the performance between the two designs?

About This Instructable

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Bio: student at SRM university , Btech mechatronics
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