Step 7: Speaker Housing Assembly

This is the fun part; assembling the speaker housing :D

Components (Pictures 1+2)
  • A backplate piece
  • 2 wall connector pieces
  • 4 connector pieces
  • A grill
  • A grill holder
  • A grill cover
  • A speaker connector "thingy" (Bottom left)
  • A speaker
  • x8 20mm M4 Bolts
  • x4 30mm M4 Bolts
  • x12 M4 Nuts
  • A front piece (In this case, it's the Snowflake) (Picture 2)

  1. Firstly, you need to take off all the sticky backing.
  2. Then you need to put 4 20mm bolts through two wall connectors and a backplate, fastened with 4 nuts. (Pictures 3+4)
  3. Next, you need to connect the four connector to the backplate using 4 20mm bolts and 4 nuts. (Pictures 5+6)
  4. I would now advise that you attach the speaker cable now, as it will be tricky to do so later on in the build.
  5. You now need to put the speaker cable through the speaker connector "thingy" as it will get stuck otherwise
  6. Next, add the speaker connector "thingy" to the four connectors and place the speaker on top. (Picture 7)
  7. Place the front on next. (In this case, it's the Snowflake) (Picture 8)
  8. Now place the grill piece and grill holder on top, as well as the grill cover. (Picture 9)
  9. Now you need to thread the 30mm bolt through the all the top parts and fasten into the nut that is in the connector (Picture 10 is the best picture I have at the moment, I will do another when I get the 30mm bolts)
very nicely done ... looks very clean ... couldn't you use boiling water to soften the plastic to avoid smells from cooking it (maybe that's not a problem)
Yes, you could use boiling water to soften the plastic - it may even work better, as it might give more evenly distributed heating :D I used a oven that is well used and I didn't smell anything apart from the acrylic plastic.
Overall, this is a clever and well thought out design. However, I think the nuts and bolts showing on the front of the amp let down its generally clean lines. Given that they are like that to hold the case together, I'd suggest putting a false white front over these, held on with either supermagnets or double sided tape with a suitable hole for the volume control. You could leave a slight gap around the volume control and sandwich an LED between the front panel and the new front to give a glow around the volume control when the amp is on.
This is a good idea, but would a line of hot glue on the inside be sufficient? As it would require less laser cutting, but it would also mean that you couldn't take the amp housing apart as easily : / Thanks for the feedback, I will experiment with your idea and see how it comes out :)
Cool idea with the bowl for bending the acrylic!
Sansa + rockbox is the best.
I have a neat pack of Instructables to talk about, today on my Blog, and your's one of them! :) <br>http://faz-voce-mesmo.blogspot.pt/2012/11/instructables-traceparts-e-noticias.html
Awesome! Thanks for including it in your blog.
Beautiful design.

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