If you have created or purchased a small MP3 amplifier and need a sweet enclosure for it, a repurposed tin might be just the thing. Follow this instruction to make one of your own.
Step 1: Find The Perfect Tin
A perfect tin may have come with cookies or kerosene in it. You may find one on eBay or in an antique shop. I got mine in the local thrift shop.
Step 2: Select A Speaker And Create A Template
Once a speaker is selected that will fit in the tin, create a template of the speaker to transfer onto the tin. Trace around the speaker and then cut the template out. Cut the center out to Size the hole size.
Step 3: Locate The Template And Transfer The Marks
Measure and mark the tin as needed to locate the template, then tape the template in place. Use a marker to trace the cut location on the tin
Step 4: Drill And Cut An Opening
Use a drill to place a hole at each corner. Next use a large kitchen knife in one of the holes to drive down and cut the tin. Use the knife in this way twice to carve out a wedge to allow shears in to finish the job. Use tin snips or heavy scissors to finish the job.
A note of caution!!! Cut tin is razor sharp, use care and protective gloves as needed to prevent a nasty cut!!
Step 5: Clean Up The Cut And Drill Speaker Mounting Screw Holes
Use a file to clean up the burrs left over from the cutting. This will remove loose material, but the edge will remain razor sharp. Line the speaker up to the hole and ensure that the cutout is good, some recutting may be needed to tweak it into shape. While the speaker is lined up, mark mounting screw holes and then drill them out!!
Step 6: Cover The Sharp Edge
Get some clear tubing such as is used on oxygen masks. Cut just enough to go around the hole. Mark a straight line on the tubing and then slit it open. Use a hot glue gun to affix the tubing over the sharp cutout. When done, the tin will be less dangerous.