I got an ipod nano in November and since have wanted an attractive speaker system for it. At work one day I noticed that the computer speakers I use worked pretty well, so I headed to the Goodwill later and found a pare of ok computer speakers for $7, After dissecting them I had a little amp and two speakers.
Step 1: Dissasemble speakers.
Here I have taken the speakers apart. I picked up the leatherman at radio shack about two months ago. Unfortunately that was before I knew about the MAKE: version of the tool.
Step 2: Speaker design
I tried out Google SketchUp
and had the basic design down for the speakers in about 30 min. I highly recommend trying SketchUp
, very easy and intuitive.
Step 3: Build the speaker boxes
I had some nice pieces of maple left over from a cabinet I built. The bottom and front are attached at a 10 deg angle. I later wished this had been 15 deg. to match the ipod nano dock angle. The hole was made with a 3" hole saw and a drill press. Later I rabbited the inside of the hole so the speaker would sit closer to the face of the front.
Step 4: Speaker box sides and horn.
I used a forsner bit to drill a 1-1/4" hole for the horn. A strait pcv union was painted black and epoxied to the horn hole. Note the burn marks around the speaker hole rabbit, hard maple and routers do not get along very well!
Step 5: Speaker nearly finnished
Step 6: Install speakers
I didn't want any screws on the face showing and the speakers were recently damaged by a curious 5 year old so I used hot melt glue to install the speakers, this should make replacement easy if I find some decent replacements.