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Pretty simple speaker, very good battery life, build in bluetooth.

It's assembled with

  • laser cut 4mm plywood (31cm x 8cm x 8cm)
  • 4x 2" drivers from small notebook speakers (EARISE AL-101, they are surprisingly good)
  • 2x 18650 3000mah
  • TP4056 charger with cell protection
  • bluetooth module
  • 3.5mm female jack
  • basic on/off switch
  • 2x 3W*2 class D amplifier (pam8403)
  • optional: 2x step-up(boost) voltage converter

Step 1: Box

The plywood was cut with "tooth" shapes so it's easier to glue. Heat from the laser bend it a litte.

Apply glue to every panel except top or back and put it together

Step 2: Back Panel..

I forgot about holes on back panel and had to improvise a little. Drill and wood file ftw.

Step 3: Back Panel

Hot glued switch, jack, TP4056 charger (I added a heatsink), pay attention to that little hole next to it and hot glue on charger LEDs, it will lead light to this hole and indicate if battery is charged or not :).

Hole one the left is on/off switch of BT module covered with wood.

Step 4: Wiring

I used a cheap bluetooth module with on/off button and jack output, so you can use it as bluetooth speaker or just as aux speaker when BT is off.

If you want a better module i recommend CSR6035/CSR6045 module (~7$ on aliexpress) but you have to figure the wiring on your own ;). http://www.aliexpress.com/item/Bluetooth-4-0-Stere...

The PAM8403 amplifier is small, powerful,power efficent... and costs nothing

http://www.aliexpress.com/item/10PCS-PAM8403-Super...

Charger - it's important to use TP4056 WITH cell protection, so they are safe from over discharge

http://www.aliexpress.com/item/2pcs-Lithium-Batter...

Capacitors that I used may be too big/useless but it's good to have one than not having it at all :D.



optional: to achieve better sound quality on higher volumes put an voltage converter (from 3.0-4.2 to. 5.0v-5.5v) before amplifier (one converter for one amp), most of the bluetooth modules uses 3-4.2v so leave it straight to battery. And you should use batteries with bigger capacity/more of batteries connected in-parallel.

(this one is nice, with 2A current) http://www.aliexpress.com/item/2pc-DC-Boost-conver...

Step 5: Soundproof the Box

Last thing, fill box with wadding or something similar. In my case it's organic cotton (don't use viscose).

Step 6: Batterylife

Cells are from disassembled 6000mah powerbank (kinda doubt they're 3000mah each).

On max volume with aux (BT off) it was playing music for over 8 hours and probably could make another 5 hours if not more.

You can finish the look with lacquer, veneer or leave as it is, looks quite nice ;).

Step 7: CAD Project

Here's my CAD project for 4mm plywood

<p>im thinking of making a bluetooth speaker but i need some help, can the charger support 4 batteries? and im thinking to buy 2 2*3w amp and 1 bluetooth, if the bluetooth is 5v do i need a step up converter ? and if the amps are 5v do i need a step up converter? sorry for bad english</p>
<p>which bluetooth module did you use</p>
<p>Gorgeous! Good job</p>
<p>Hello, could you please tell me ? When you turn on bluetooth does it turn off the audio IN jack? If it doesn't wouldn't it be a problem because if you tried to coonnect the aux to a device and bluetooth to another device wouldn't the sound &quot;confilct&quot; because bluetooth isnt turned off vice versa?</p>
<p>Use a jack which breaks contact from the B/T module to the amplifier when Aux is plugged in. For example, for 85 cents US: <a href="http://www.allelectronics.com/make-a-store/item/smj-6/3.5mm-stereo-mini-phone-jack-w/2-nc-shunts/1.html" rel="nofollow">http://www.allelectronics.com/make-a-store/item/smj-6/3.5mm-stereo-mini-phone-jack-w/2-nc-shunts/1.html</a></p>
<p>If you use more advanced bluetooth module like CSR8635 you can put AUX directly to it - so if you plug jack in, it would play from aux not from bluetooth. Also you have possibility to put there physical buttons like play, pause or even a microphone for calls.</p>
<p>Yes it would be a problem, it's simply connected bluetooth and aux to same channel without any weird circuit so it can only play one thing. </p><p>Don't know why would you plug two sources into speaker, it's meant to be portable not connected to PC or something. </p>
<p>I found a pair of Phillips 8 ohm speakers. I dont know other specifications about it so which amplifier to use. Kindly help</p>
<p>What amplifier you use is not as important as <strong>not overdriving</strong> the amplifier. It takes very little distortion to blow out speakers.</p><p>If you are happy with just having noise (music, sound) you can probably get away with 2 to 5 Watts/channel or less.</p><p>Since I really want to blast the neighborhood (not really, but I like to have a powerful system in my vehicle), I found a 100 W/channel class 'D' stereo amplifier which runs on anything from 12 to 26 Volts DC online for $12.77 USD including shipping from eBay (TPA3116 Dual channel audio amplifier). It cost more for a power supply (a 24 V switch-mode model for LED strip lights for $24 USD) than it did for the amp which I won't even be using when I install it in my van.</p><p>There is also a Bluetooth TDA7492P 50 W/channel amplifier on eBay for $11.69. It also runs on anything from 12 to 26 VDC.</p><p>Both of these units are very small: less than 5 inches long and they output power as advertised.</p><p>I hope this helps.</p>
what did it cost you????
<p>box 8$, bluetooth 5$, batteries 4$, speakers (with amplifiers from them) 15$ = 32$</p>
<p>Where did you find the speakers so cheap? They are at least $11.50 each niow.</p>
<p>I had a coupon, but these speakers looks exactly like these and probably are same</p><p><a href="http://www.ebay.com/itm/Mini-Portable-USB-Audio-Music-Player-Speaker-for-cellphone-smar-MP3-Laptop-PC-SU-/381210077737?hash=item58c1e42a29:g:~ksAAOSw7aBVGMCM" rel="nofollow">http://www.ebay.com/itm/Mini-Portable-USB-Audio-Mu...</a></p><p><a href="http://www.ebay.com/itm/New-USB-Stereo-Speakers-For-Laptop-Desktop-Computer-MP3-Music-Player-Black-/121320391663?hash=item1c3f4243ef:g:ot8AAOSwX6VTxtjB" rel="nofollow">http://www.ebay.com/itm/New-USB-Stereo-Speakers-Fo...</a></p>
<p>how much loud the sound is for this speaker</p>
<p>Great wireless speaker!</p>
<p>Did you fill it up completely with cotton?</p>
<p>Yes</p>
<p>that's very good....!</p>
<p>This is a great looking speaker set up. Really like the way it turned out!</p>

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