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Laser-cut Speaker with Amplifier

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Picture of Laser-cut Speaker with Amplifier
If you have access to a laser you can make laser-cut own speakers out of 1/4" plywood.
If not, you can use online laser cutting service such as Outfab and cut it out for under a hundred bucks.
You can use old speakers for the components like I did, or purchase the speakers and amplifier from your local electronics store.
An old stereo system should have everything you need.
 
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Step 1: Harvest parts

Picture of Harvest parts
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I got my speakers and amplifier from old speakers that sound pretty good but are hideous.
After taking the old speakers apart, analyze them and trace where the power and audio signals go. You'll need to know what to connect where.

Step 2: Design and Laser-cut

Picture of Design and Laser-cut
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I uploaded the design in SVG format to http://www.fabout.com
You can customize the design before you cut it.
If you don't have a laser cutter you can submit it to online laser cutting service such as Outfab (3sqf costs $92 including shipping.)

Step 3: Parts

Picture of Parts
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These are all parts necessary for the assembly.
For fastening the plywood I used 1/4" square nuts and 6/32 3/4" Torx screws.
I also sanded the wood to make it smooth but also so it fits in the slots.
By design, all slots were made smaller than the thickness of the plywood, so that everything can fit well after sanding.

Step 4: Assembly

Picture of Assembly
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Now the easy part - just put everything together like Lego, solder the power and audio cable and screw the sides.
I also put some hot glue on power and audio cable inside in order to prevent them from being ripped out.
Wouldn't these sound better if they were sealed?
dimovi (author)  Brutus Ultimatum5 months ago
Yes they would. A friend of mine who designs speakers said that the bigger the speaker the important it is to be sealed except for a small hole. I put holes all over it so the amplifier can stay cool. Ideally the heatsink would stick out of the back and no air flow would be necessary inside.
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