Introduction: Portable Bluetooth Speaker | Carbon Black

Hi!

I have recently built a Portable Bluetooth Speaker for my brother's Birthday, so I thought, why not share the details of it with you guys?

Feel free to check out my video on YouTube of making the speaker! : Portable Bluetooth Speaker Build

Step 1: Design and Materials

Picture of Design and Materials

https://goo.gl/5hGugSI designed the speaker on Sketchup. I chose to use MDF of 6mm thickness for the enclosure, since it is easy to cut and sand to achieve the desired shapes. For the control panel I used 3mm plywood, which I later wrapped with Carbon Fiber Vinyl. The box was also wrapped with Faux Leather Vinyl.

I was not able to include all parts and materials used in the build, since some of them are discontinued or bought from local stores. Electronics, tools and other parts list:

Step 2: Making the Enclosure

Picture of Making the Enclosure

My main tool in this build was the Makita Jigsaw. Since I do not have access to a table saw, my cuts with the jigsaw had to be somewhat precise and accurate.

Using the semi-DIY drill and the jigsaw, I was able to drill holes for the speakers, control panel and the passive radiator.

After the cuts have been made, a piece of sandpaper was used to round over the corners and give the enclosure a nicer look and feel. A bigger size drill bit was used to countersink the holes on the back panel of the speaker.

I did not show it in the video, but I glued 4 pieces of thicker wood inside the enclosure to allow the back panel to rest against something. Only a few more steps left!

Step 3: Applying the Vinyls

Picture of Applying the Vinyls

I'd say this is the most time consuming and frustrating part of the build. Applying the Vinyls. I started with applying the Carbon Fiber vinyl to the control panel, front and back baffles. This material is somewhat resistant to scratches and cuts. It sticks well to a prepared surface and is easily stretched with the persuasion of a heat gun.

Since it was my first time using this vinyl, I did end up with torn vinyl around the tweeter holes, as you can see in the video. But a little dab with a black marker covered the mistakes. The vinyl really makes the subtle curves of the ports pop in sunlight, showing the fake weave in the vinyl.

Then I used contact cement to glue in the passive radiator and apply the faux leather vinyl. The tweeters are held in place with a healthy amount of hot glue. I covered the enclosure and the vinyl with contact glue, gave it a few minutes to dry and then stuck them together. The leather vinyl is stretchable, so I was able to form it around the corners and roundovers. After all that hassle I glued in the control panel.

Step 4: Guts of the Speaker

Picture of Guts of the Speaker

I used hot glue to hold the Crossovers in place.

Then there was a lot of soldering. Wiring the switches and ports, mounting them in, soldering the battery together. The electronics turned out to be working great, I was able to insert a small LED light in the control panel for the Bluetooth. The Power Button looks awesome on this speaker, it doesn't glow too bright, but the white light gives it that unique and eye-catching look.

To me, the best part about this speaker is the Power Button OFF action. When the speaker is turned off, the Power Button light slowly fades away, it does not shut down immediately. I guess the reason why it does so, is that the capacitors in the amplifier are slowly discharging in to the LED light in the button. You can see what I am talking about at the end of the build video.

Step 5: Final Assembly

Picture of Final Assembly

Finally I was able to insert the front panel on to the enclosure and admire my project at its glory. I used a long piece of foam-like material for the gasket on the back panel to seal the speaker. Then I added my logo on the back side and screwed down the back panel.

I then stuck on a few pairs of adhesive pads on the bottom, gave the speaker a charge and it was now ready for some action!

Thank You guys for taking a look at my speaker, I hope You enjoyed! Make sure to check my YouTube Channel for more content!

Thanks!

- Donny

Comments

toorland (author)2017-11-01

Just one more thing, is it hard to add a volume control to the speaker?

toorland (author)2017-10-30

is it possible to chain more than trhee batteries together?

Donny Terek (author)toorland2017-11-01

Hi! Of course it is possible. It simply depends whether you want your battery pack to have a higher capacity or voltage. If you are reaching for a higher capacity - connect the batteries in parallel. If you are aiming for a higher voltage - connect the batteries in series and use an appropriate battery management system. For example, if you want to connect 3 batteries in series, use a 3S BMS. If you want 4 batteries in your pack, use a 4S BMS, and so on.

toorland (author)Donny Terek2017-11-01

thank you for the good answer :) I ordered all the components i need for this build yesterday and i am stoked to get started on it. I love the design on your speaker :)))

Tessaract. (author)2017-10-26

Is there any chance that you'd post the wiring diagram for this project?

Donny Terek (author)Tessaract.2017-10-28

Hi! Sorry for the late reply, I have placed the wiring diagram, feel free to use it. Good luck!

ElviejoYil (author)2017-10-23

You made the best looking Bluetooth speaker, what amazing job!
I see you used a 3.5 jack, but where do you conect it? Im making a speaker too, but i don't know how to conect this jack to plug mi headphones, can you help me?

And once again, excellent job!

Donny Terek (author)ElviejoYil2017-10-24

Thank you so much! I truly appreciate that.
Yes I did use it and it is not for headphones, it goes directly to the amplifier board.

rtru97121416 (author)2017-10-03

Excellent work. My daughter asked me for a portable Bluetooth speaker. Instead of buying it I want to surprise her with one I made. I would like to try making yours if it's ok. Could you give me the dimensions of the enclosure.

Thank you.

Donny Terek (author)rtru971214162017-10-07

Thank You! I absolutely love and support your idea. Sure, the height of the box is 124 mm, the length is 260 mm and the width is 100 mm. Feel free to contact me if you need any building tips or advice! Good luck!

robertob96 (author)2017-09-02

Me gusta bastante el resultado. Cogiendo ideas para uno similar.

Pero veo que hay componentes como el modulo Setp Down que no esta en la lista

DjSchtiel (author)2017-08-17

I must say that you sir, got me jealous.. I was wondering how ugly the box is when I saw the start of the YT video. And in the end of the video, I was astonished! Very good craftmanship! Keep up the VERY good work! I will do something like this myself (looking for ideas).

Sorry if my grammar is not so good, Im a Finn.. :D

Donny Terek (author)DjSchtiel2017-08-17

Hi! Thank You so much for your kind words! I am working on a new project that I will release in fall, so I'm trying my best to keep up! Your grammar is just perfect though! By the way, I'm Lithuanian, so not that far away from you!

diogosodre (author)2017-08-13

How long the battery lasts?

Donny Terek (author)diogosodre2017-08-16

Hi! The battery lasts around 5 hours, but have in mind that I used old cells from a laptop.

vishnumaiea (author)2017-07-29

That's a really nice build. You have my vote ;)

Donny Terek (author)vishnumaiea2017-07-30

Thank you so much! I appreciate that.

Donny Terek (author)2017-07-28

Hi everyone!

I have updated the parts list, you can check it in Step 1!

Swansong (author)2017-07-25

That looks nice! It came out really well :)

Donny Terek (author)Swansong2017-07-28

Thank you so much! I Appreciate that!

About This Instructable

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Bio: Nice to meet you! I'm Donny from Lithuania and I have a passion for designing aesthetic, yet durable and practical projects. Check these links ... More »
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